Table of Contents
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1
Introduction ............................................................................................................. 4
2
Specification ........................................................................................................... 5
2.1
2.2
2.3
2.4
2.5
Control unit ...................................................................................................... 8
2.5.1 Microswitches ........................................................................................ 8
2.5.2 Accelerator unit ...................................................................................... 8
2.5.3 Other analog control unit ......................................................................... 9
2.5.4 Speed feedback ................................................................................... 10
2.5.5 Steering angle transducer ..................................................................... 10
2.6
2.7
Operational features ...................................................................................... 13
2.8
Diagnosis ..................................................................................................... 14
2.9
Thermal consideration ................................................................................... 14
2.12 Main contactor and emergency switch ........................................................... 15
3
4
Installation ............................................................................................................. 17
4.1
Connection cables ........................................................................................ 17
4.2
Contactors .................................................................................................... 17
4.3
Fuses ............................................................................................................ 17
4.4
4.5
4.6
Encoder installation ....................................................................................... 23
4.7
CANBUS connector description .................................................................... 24
4.7.1 "Dualac2" Controller in stand-alone configuration .................................. 24
4.7.2 "Dualac2" Controller is a termination module in the canbus net ............. 24
4.7.3 "Dualac2" Controller is a repetition module in the canbus net ................ 25
4.8
Description of power connections.................................................................. 26
4.8.1 "Dualac2" ............................................................................................. 26
4.8.2 "Dualac2 Power" .................................................................................. 27
4.9
Mechanical drawing ...................................................................................... 32
4.10 Connection drawing - "Dualac2" and "Dualac2 Power" standalone ................ 36
INDEX
................................................................................. 12
................................................................................... 16
...................................................... 14
......................................... 15
Page 1
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Summary of Contents for Zapi DUALAC2
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Page 1: Table Of Contents
CANBUS connector description ..............24 4.7.1 "Dualac2" Controller in stand-alone configuration ........24 4.7.2 "Dualac2" Controller is a termination module in the canbus net ..... 24 4.7.3 "Dualac2" Controller is a repetition module in the canbus net ....25 Description of power connections..............26 4.8.1 "Dualac2"... - Page 2 5.6.1 Functional configuration (see 5.4) ............60 5.6.2 Parameter programming (see 5.5) ............60 5.6.3 "Dualac2" and "Dualac2 Power" Tester: user can verify the state of the following parameters: ..................60 5.6.4 "Dualac2&hp" and "Dualac2&hp Power" Tester: user can verify the state of the following parameters: ................
- Page 3 "Dualac2" and "Dualac2&hp" Inverter diagnostic ..........72 Traction related fault codes ................72 Analysis of traction related alarms displayed on console........ 76 Pump related fault codes ................81 Analysis of pump related alarms displayed on console ........82 Recommended Spare parts for inverter ............. 83 Periodic Maintenance to be repeated at times indicated ........
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Page 4: Introduction
1 INTRODUCTION Within the ZAPIMOS family, the DUALAC2 inverter is the model suitable for control of pairs of 3.0kW to 7.0kW motors. The DUALAC2&HP can also control a DC-Series pump motor, up to 15kW. These controllers have been expressly designed for battery powered applica- tions, traction and hydraulic functions. -
Page 5: Specification
2 SPECIFICATION 2.1 TECHNICAL SPECIFICATIONS - "DUALAC2" Inverter for pairs of AC asynchronous 3-phase motors Regenerative braking functions Can-bus interface Digital control based upon a microcontroller (one per each motor) Voltage: .................. 24 - 36 - 48 - 72 - 80V Maximum current (24V): ........ -
Page 6: Technical Specifications - "Dualac2&Hp
2.2 TECHNICAL SPECIFICATIONS - "DUALAC2&HP" Inverter for pairs of AC asynchronous 3-phase motors plus chopper for DC series pump motor. Regenerative braking functions Can-bus interface Digital control based upon a microcontroller (one per each AC motor) Voltage: .................. 24 - 36 - 48 - 72 - 80V Maximum current (24V): ........ -
Page 7: Technical Specifications - "Dualac2 Power
BLOCK DIAGRAM CHOPPER 2.3 TECHNICAL SPECIFICATIONS - "DUALAC2 POWER" Inverter for pairs of AC asynchronous 3-phase motors Regenerative braking functions Can-bus interface Digital control based upon a microcontroller (one per each AC motor) Voltage: .................. 24 - 36 - 48 - 72 - 80V Maximum current (24V): ........ -
Page 8: Technical Specifications - "Dualac2&Hp Power
2.4 TECHNICAL SPECIFICATIONS - "DUALAC2&HP POWER" Inverter for pairs of AC asynchronous 3-phase motors plus chopper for DC series pump motor Regenerative braking functions Can-bus interface Digital control based upon a microcontroller (one per each AC motor) Voltage: .................. 24 - 36 - 48 - 72 - 80V Maximum current (24V): ........ -
Page 9: Other Analog Control Unit
Sensors can be digital (on/off sensor, normally closed) or analog. See also chapter 5.4 for more explanation. 3) In the versions with integrated pump chopper (DUALAC2&HP and DUALAC2&HP POWER), it is possible to input to the controller an analog signal for proportional lifting. -
Page 10: Speed Feedback
2.5.4 Speed feedback The traction motors control is based upon the motor speed feedback. The speed trans- ducer is an incremental encoder, with two phases shifted at 90°. The encoder can be of different types : power supply: +5V or +12V electric output: open collector ( NPN or PNP), push-pull For more details about encoder installation see also chapter 4.6. - Page 11 Option #2 = tables for 4 wheels trucks without driving wheels counter-rotation (the internal wheel does not inverts the direction). The truck data have to be communicated to Zapi, so that it is possible to put in the software the correct steering table.
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Page 12: Protection Features
2.6 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 13: Operational Features
- Memory of the last five alarms with relative hour-meter and temperature displayed on the console. - Diagnostic function with Zapi handset for checking main parameters. - Built in BDI feature. - Flash memory, sw downloadable via serial link and via CANBUS. -
Page 14: Diagnosis
2.8 DIAGNOSIS The microprocessors continually monitor the inverter and carry out a diagnostic procedure on the main functions. The diagnosis is made in 4 points 1) Diagnosis on key switch closing that checks: watchdog circuit, current sensor, capaci- tor charging, phase's voltages, contactor drivers, can-bus interface, if the switch se- quence for operation is correct and if the output of accelerator unit is correct, correct synchronization of the two µCS, integrity of safety related inputs hardware. -
Page 15: Susceptibility And Electromagnetic Emission
EN50081-2). 2.12 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 16: Safety And Protection
It is strongly suggested to connect the machine safety related devices to these four inputs, in order to increase machine safety. ZAPI is always available to cooperate with the customer in order to evaluate instal- lation and connection solutions. Furthermore, ZAPI is available to develop new SW or HW solutions to improve the safety of the machine, according to customer requirements. -
Page 17: Installation
4 INSTALLATION Install the controller 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 18: Description Of Connectors - "Dualac2" And "Dualac2 Power
4.4 DESCRIPTION OF CONNECTORS - "DUALAC2" AND "DUALAC2 POWER" CAN_H High level CANBUS. CANT_H CANBUS termination output, 120 ohm internally connected to CAN_H. Connect to CAN_L_OUT to insert the termination. CAN_POS Positive of CAN circuit; to be used in case of optoisolated CANBUS. - Page 19 PENC_R Positive of right motor encoder power supply (+5V/+12V). NENC_R Negative of right motor encoder power supply. Connected to +Batt trough a microswitch and a 10A fuse in series. Common of FW / REV / HB / PB / SEAT / ENABLE microswitches. SEAT Seat presence signal;...
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Page 20: Description Of Connectors - "Dualac2&Hp" And "Dualac2&Hp Power
4.5 DESCRIPTION OF CONNECTORS - "DUALAC2 HP" AND "DUALAC2 & & POWER" CAN_H High level CANBUS. CANT_H CANBUS termination output, 120 ohm internally connected to CAN_H. Connect to CAN_L_OUT to insert the termination. CAN_POS Positive of CAN circuit; to be used in case of optoisolated CANBUS. - Page 21 PENC_R Positive of right motor encoder power supply (+5V/+12V). NENC_R Negative of right motor encoder power supply. Connected to +Batt trough a microswitch and a 10A fuse in series. Common of FW / REV / HB / PB / SEAT / ENABLE microswitches. SEAT Seat presence signal;...
- Page 22 D1 -BATT Negative output. D2 2ND Second hydraulic speed input, active high. D3 1ST First hydraulic speed input, active high. D4 ENABLE Input for proportional lifting enable; active high. Common output of microswitches (+BATT). D6 5TH Fifth hydraulic speed input, active high. D7 4TH Fourth hydraulic speed input, active high.
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Page 23: Encoder Installation
4.6 ENCODER INSTALLATION 1) Dualac2 and Dualac2&hp card is fit for different types of encoder. To control AC motor with Zapi inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90°. The encoder power supply can be +5 or +12V. It can have different electronic output. -
Page 24: Canbus Connector Description
4.7 CANBUS CONNECTOR DESCRIPTION Dualac2 Controller has a canbus interface, so it has been designed to work in a can network together with other electronic modules, exchanging informations over the canbus network. Furthermore, the exchange of informations between master and slave microcontrollers is based on the canbus, as well. -
Page 25: Dualac2" Controller Is A Repetition Module In The Canbus Net
4.7.3 "Dualac2" Controller is a repetition module in the canbus net The canbus built-in termination resistances are not inserted. Page 25... -
Page 26: Description Of Power Connections
4.8 DESCRIPTION OF POWER CONNECTIONS 4.8.1 "Dualac2" View of the power bars: Negative of the battery. Positive of the battery; if the power fuse is not present, the positive cable coming from LC contact must be connected to this power connection. -
Page 27: Dualac2 Power
4.8.2 "Dualac2 Power" View of the power bars: Negative of the battery. Positive of the battery; if the power fuse is not present, the positive cable coming from LC contact must be connected to this power connection. +BTF Positive of battery before power fuse, must be connected to positive cable coming from LC contact. -
Page 28: Dualac2&Hp
4.8.3 "Dualac2&hp" View of the power bars: Negative of the battery. Positive of the battery; if the power fuse is not present, the positive cable coming from LC contact must be connected to this power connection. Page 28... - Page 29 +BTF Positive of battery before power fuse, must be connected to positive cable coming from LC contact. Um; Vm; Wm Connection bars of the three right motors phases; follow this se- quence and the indication on the motor. Us; Vs; Ws Connection bars of the three left motors phases;...
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Page 30: Dualac2&Hp Power
4.8.4 "Dualac2&hp Power" View of the power bars: Negative of the battery. Positive of the battery; if the power fuse is not present, the positive cable coming from LC contact must be connected to this power connection. Page 30... - Page 31 +BTF Positive of battery before power fuse, must be connected to positive cable coming from LC contact. Um; Vm; Wm Connection bars of the three right motors phases; follow this se- quence and the indication on the motor. Us; Vs; Ws Connection bars of the three left motors phases;...
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Page 32: Mechanical Drawing
4.9 MECHANICAL DRAWING Dimensions of "Dualac2": Page 32... - Page 33 Dimensions of "Dualac2 Power": Page 33...
- Page 34 Dimensions of "Dualac2 hp": & Page 34...
- Page 35 Dimensions of "Dualac2 hp Power": & Page 35...
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Page 36: Connection Drawing - "Dualac2" And "Dualac2 Power" Standalone
4.10 CONNECTION DRAWING - "DUALAC2" AND "DUALAC2 POWER" STANDALONE Page 36... -
Page 37: Connection Drawing - "Dualac2&Hp" And "Dualac2&Hp Power" Standalone
4.11 CONNECTION DRAWING - "DUALAC2&HP" AND "DUALAC2&HP POWER" STANDALONE Page 37... -
Page 38: Programming & Adjustments Using Digital Console
5 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE 5.1 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 “B” connector of the inverter. 5.2 DESCRIPTION OF CONSOLE & CONNECTION Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum "Release Number 3.02". -
Page 39: Description Of Standard Console Menu
5.3 DESCRIPTION OF STANDARD CONSOLE MENU 5.3.1 "Dualac2" and "Dualac2 Power" menu configuration 5.3.1.a Master Page 39... -
Page 40: Slave
5.3.1.b Slave Page 40... -
Page 41: Dualac2&Hp" And "Dualac2&Hp Power" Menu Configuration
5.3.2 "Dualac2&hp" and "Dualac2&hp Power" menu configuration 5.3.2.a Master Page 41... -
Page 42: Slave
5.3.2.b Slave Page 42... -
Page 43: Function Configuration
5.4 FUNCTION CONFIGURATION 5.4.1 "Dualac2" and "Dualac2 Power" - Master 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"... - Page 44 6 PEDAL BRAKING - ANALOG: the mechanical brake pedal has a switch and a potentiometer installed. When the accelerator is released and the pedal brake is pushed the inverter performs an electrical braking whose intensity is proportional to the brake pedal potentiometer.
- Page 45 6 MAX STEER LEFT: this is the function to record in the controller EEPROM the steering poti output voltage when the wheels are fully turned left (minimum of the steering poti range). 7 SET STEER 0 POS: this is the function to record in the controller EEPROM the steering poti output voltage when the wheels are straight.
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Page 46: Dualac2" And "Dualac2 Power" - Slave
(PWM output C26) 16 AUX OUTPUT VOLTAGE: this parameters adjusts the Electric brake coil voltage (PWM output C28). 5.4.2 "Dualac2" and "Dualac2 Power" - Slave Using the config menu of the programming console, the user can configure the follow- ing functions. -
Page 47: Dualac2&Hp" And "Dualac2&Hp Power" - Master
5.4.3 "Dualac2&hp" and "Dualac2&hp Power" - Master See chapter 5.4.1. 5.4.4 "Dualac2&hp" and "Dualac2&hp Power" - Slave Using the config menu of the programming console, the user can configure the follow- ing functions. SUBMENU "SET OPTIONS" Not available. SUBMENU "ADJUSTEMENT"... - Page 48 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 49 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 50 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 51 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 51...
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Page 52: Parameter Regulation
5.5 PARAMETER REGULATION 5.5.1 "Dualac2" - Master The following parameters can be modified: ACC DELAY: determines the acceleration ramp. RELEASE BRAKING: controls the deceleration ramp when the travel request is released. INVERSION BRAKING: controls the deceleration ramp when the direction switch is inverted during travel. -
Page 53: Dualac2" - Slave
100 Hz to 0 Hz. This is the ideal ramps calcu- lated by the software; the real ramp could change as a function of motor control pa- rameter setting and, obviously, as a function of the load. 5.5.2 "Dualac2" - Slave The menu is not available. Page 53... -
Page 54: Dualac2&Hp" - Master
5.5.3 "Dualac2&hp" - Master The following parameters can be modified: ACC DELAY: determines the acceleration ramp. RELEASE BRAKING: controls the deceleration ramp when the travel request is released. INVERSION BRAKING: controls the deceleration ramp when the direction switch is inverted during travel. -
Page 55: Dualac2&Hp" - Slave
5.5.4 "Dualac2&hp" - Slave Here following the list of parameters which can be set in this menu: PU. - Page 56 COMPENSATION: this parameter sets the voltage compensation (∆V) applied to the motor when the proportional lifting function is active. The value of this ∆V applied to the motor is a function of the motor current. Aim of this function is to reduce, as for as possible, the speed change when the motor is loaded.
- Page 57 12 4TH SPEED FINE: this parameter sets the voltage compensation (∆V) applied to the motor when the 4th speed request is active. The value of ∆V applied to the motor is a function of the motor current. Aim of this function is to reduce, as for as possible, the speed change when the motor is loaded.
- Page 58 The following table shows all the values of parameters. PARAMETER PROGRAMMED LEVEL UNIT PUMP ACCELER DELAY (*) Sec. PUMP DECELER DELAY (**) Sec. SPEED LIMIT 0 - 100 CREEP SPEED 0 - 100 COMPENSA TION 0 - 100 1ST SPEED FINE 0 - 100 1ST SPEED COMP 0 - 100...
- Page 59 After changing a parameter, press ENTER to confirm data when requested by the mes- sage on the console. Parameters modified and optimized on one unit can be stored by the Zapi Pc-console (SAVE) and then downloaded (RESTORE) to another controller, thus allowing fast and standardized settings (see Pc-console manual for details).
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Page 60: Programming Console Functions
5.6 PROGRAMMING CONSOLE FUNCTIONS 5.6.1 Functional configuration (see 5.4) 5.6.2 Parameter programming (see 5.5) 5.6.3 "Dualac2" and "Dualac2 Power" Tester: user can verify the state of the fol- lowing parameters: MASTER SLAVE motor voltage (%) motor voltage (%) frequency (Hz) -
Page 61: Of The Following Parameters
5.6.4 "Dualac2&hp" and "Dualac2&hp Power" Tester: user can verify the state of the following parameters: MASTER SLAVE motor voltage (%) motor voltage (%) frequency (Hz) frequency (Hz) encoder (Hz) encoder (Hz) slip value (Hz) slip value (Hz) current rms (A) current rms (A) temperature (°C) -
Page 62: Sequence For Ac Inverter Traction Setting
5.7 SEQUENCE FOR AC INVERTER TRACTION SETTING When the "Key Switch" is closed, if no alarms or errors are present, the Console Display will be showing the Standard Zapi Opening Display. If the controller is not configured to your requirements, follow the sequence detailed here following. -
Page 63: Tester: Description Of The Function
In the following chapter a list of relative measurements for differ- ent configurations. 5.8.1 "Dualac2" and "Dualac2 Power" - Master 1) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is ex- pressed as a percentage of the full voltage (which depends of the battery voltage). -
Page 64: Dualac2" And "Dualac2 Power" - Slave
22) BATTERY VOLTAGE: level of battery voltage measured at the input of the key switch. 23) BATTERY CHARGE: the percentage Charge level of the battery. 5.8.2 "Dualac2" and "Dualac2 Power" - Slave 1) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is ex- pressed as a percentage of the full voltage (which depends of the battery voltage). -
Page 65: Dualac2&Hp" And "Dualac2&Hp Power" - Master
12) BATTERY VOLTAGE: level of battery voltage measured at the input of the key switch. 5.8.3 "Dualac2&hp" and "Dualac2&hp Power" - Master 1) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is ex- pressed as a percentage of the full voltage (which depends of the battery voltage). -
Page 66: Dualac2&Hp" And "Dualac2&Hp Power" - Slave
22) BATTERY VOLTAGE: level of battery voltage measured at the input of the key switch. 23) BATTERY CHARGE: the percentage Charge level of the battery. 5.8.4 "Dualac2&hp" and "Dualac2&hp Power" - Slave 1) MOTOR VOLTAGE: this is the voltage supplied to the motor by the inverter; it is ex- pressed as a percentage of the full voltage (which depends of the battery voltage). - Page 67 7) SEAT SWITCH: the level of the Seat Microswitch digital input. ON / +VB = input active, switch closed. OFF / GND = input non active, switch open. 8) FORWARD SWITCH: the level of the Forward direction digital input FW. ON / +VB = input active, switch closed.
- Page 68 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 69: Other Functions
6 OTHER FUNCTIONS 6.1 SAVE AND RESTORE FUNCTION SAVE function allows to transfer controller parameters to the Pc console memory. With this function, a copy of the controller set of parameters can be retained in a Pc and downloaded to another controller (see RESTORE). RESTORE function allows to download controller parameters from the Pc console memory to the controller Eeprom. -
Page 70: 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 70... -
Page 71: 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 71... -
Page 72: "Dualac2" And "Dualac2&Hp" Inverter Diagnostic
7 "DUALAC2" AND "DUALAC2&HP" INVERTER DIAGNOSTIC 7.1 TRACTION RELATED FAULT CODES ALARM Mast- Slave CONTROLLER DESCRIPTION Condition that has to occur STRING STATUS to come out from alarm status Init Stby Motor running "WATCHDOG" Alarm: the Watchdog -If the alarm is present in... - Page 73 ALARM Mast- Slave CONTROLLER DESCRIPTION Condition that has to occur STRING STATUS to come out from alarm status Init Stby Motor running 53 "STBY I HIGH" Alarm: wrong voltage in -If the alarm is present in the current sensor Init status,remove the feedback circuit alarm condition -If the alarm has occurred...
- Page 74 ALARM Mast- Slave CONTROLLER DESCRIPTION Condition that has to occur STRING STA TUS to come out from alarm status Init Stby Motor runni- 38 "CONTACTOR Alarm: line contactor To remove alarm cause OPEN" power contact does not within a timeout; if the pull-in timeout is elapsed, it is necessary to re-cycle the...
- Page 75 ALARM Mas- Sla- CONTROLLER DESCRIPTION Condition that has to occur STRING STA TUS to come out from alarm status Init Stby Motor running 13 "EEPROM KO" Warning: Eeprom fault, To remove Warning cause controller will use default parameters "HIGH Warning: Master or Slave To remove Warning cause TEMPERA- or both temperature...
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Page 76: Analysis Of Traction Related Alarms Displayed On Console
7.2 ANALYSIS OF TRACTION RELATED ALARMS DISPLAYED ON CONSOLE 1. WATCH DOG It is a self-diagnosing test within the logic between Master and Slave µcontrollers. This alarm could also be caused by a canbus malfunctioning, which blinds Master-Slave communication. So, before replacing the controller, check the canbus. 2. - Page 77 Possible reasons: a) the charging resistance is opened. b) The charging circuit has a failure. c) There is a problem in the power section. 8. MAIN CONTACTOR ALARMS COIL SHORTED: When the key is switched ON the µController checks the LC coil driver shortcircuit protection hardware.
- Page 78 10. STEER SENSOR KO This is an alarm which signals an out of range of the steering potentiometer signal. The fault condition is entered in these two following conditions: - the "Set steer 0 pos" (straight wheels programmation) parameter is wrong (lower than "Set steer min"...
- Page 79 17. EEPROM KO Fault in the area of memory in which the adjustment parameters are stored; this alarm does not inhibits truck operation, but the controller will use default parameters. If the defect persists when the key is switched OFF and ON again, replace the logic. If the alarm disappears, remember that the parameters stored previously have been can- celled and replaced by the default values.
- Page 80 24. THERMIC SENSOR KO The range of inverter temperature sensor is always checked and a warning is signalled if it is out of range. When this alarm is signalled, the maximum current of the controller is reduced to halt. 25. WAITING FOR NODE #4 The Slave has detected a failure, the Master cannot close the main contactor because of the alarm status of the Slave (which the Master knows by the CAN-BUS line).
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Page 81: Pump Related Fault Codes
7.3 PUMP RELATED FAULT CODES ALARM Mas- Sla- CONTROLLER DESCRIPTION Condition that has to occur STRING STATUS to come out from alarm status Init Stby Motor running "PUMP VMN Alarm: wrong voltage -If the alarm is present in Init LOW" output of pump chopper;... -
Page 82: Analysis Of Pump Related Alarms Displayed On Console
7.4 ANALYSIS OF PUMP RELATED ALARMS DISPLAYED ON CONSOLE 1. PUMP VMN LOW The pump chopper power output is feedback to the µC. If this feedback voltage is not coherent with the applied PWM, this fault condition is signalled. There could be many causes: - failure in the pump chopper power section - failure in the pump chopper driving section... -
Page 83: 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 C29523 SW 180 80V Single Pole Contactor C29522 SW 180 48V Single Pole Contactor C29508 SW 180 24V Single Pole Contactor Page 83... -
Page 84: 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 85 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 DUALAC2 INVERTER OPERATING HANDBOOK AND FUNCTION DESCRIPTION...
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