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Zapi AC-1 SSL User Manual
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Zapi AC-1 SSL User Manual

Zapi AC-1 SSL User Manual

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ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259
e-mail: zapi@zapispa.it – web: www.zapispa.it
EN
FREE VERSION
User Manual
AC-1 SSL
SENSORED

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  • Page 1 ELECTRONIC • OLEODYNAMIC • INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259 e-mail: zapi@zapispa.it – web: www.zapispa.it FREE VERSION User Manual AC-1 SSL SENSORED...
  • Page 2 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.
  • Page 3 Contents INTRODUCTION ........................6 SPECIFICATION ........................6 Technical specifications....................6 Block diagram ......................6 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT..6 Microswitches ......................6 Accelerator unit......................6 Other analog control unit ....................6 Analog motor thermal sensor input................6 Speed feedback......................6 PROTECTION FEATURES ....................6 SAFETY AND PROTECTION..................6 Passive emergency cell ....................6 OPERATIONAL FEATURES ....................6 Diagnosis ........................6...
  • Page 4 Config menu “ADJUSTMENTS” functions list ..........6 12.4.3 Main menu “PARAMETER CHANGE” functions list........6 12.4.4 Zapi menu “HARDWARE SETTINGS” functions list ........6 12.4.5 Zapi menu “SPECIAL ADJUSTMENTS” functions list........6 12.4.6 Main menu “TESTER” functions list ............. 6 13 OTHER FUNCTIONS ......................
  • Page 5 APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN GRAPHIC AND LAYOUT PROJECT MANAGER TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Publication N°: AESZP0BA Edition: November 2004 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 5/73...
  • Page 6 AC1 and the MDI-PRC has been already developed in a standard handling here descripted. MDI-PRC is a Zapi module to be mounted on the dashboard of the truck to inform with a display about the state of the truck and provided with a Leds battery charge indicator.
  • Page 7 2 SPECIFICATION 2.1 Technical specifications Inverter for AC asynchronous 3-phase motors Regenerative braking Can-bus interface Digital control using a microcontroller Encoder Interface Voltage: ....................24 – 36 - 48V Maximum current (24V,36V): ............250A (RMS) for 2' Maximum current (48V):............. 215A (RMS) for 2' Booster (24V, 36V):............270 (RMS) for 10 seconds Operating frequency:..........8kHz with center aligned PWM External temperature range: ..............
  • Page 8 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The AC1 controller needs some external parts in order to work. The following devices complete the kit for the AC1 installation. 3.1 Microswitches The microswitches must have a contact resistance lower than 0.1Ω and a leakage current lower than 100µA.
  • Page 9 3.3 Other analog control unit Input CNA#18 is an analog input, whose typical application is a proportional command to enable a lifting and a lowering proportional Valves. It is possible to use this input for an alternative function is a proportional braking. It should be in a 3 wire configuration.
  • Page 10 4 PROTECTION FEATURES The AC1 is protected against some controller injuries and mulfunctions. These are: 1) Battery polarity inversion It is necessary to fit a MAIN CONTACTOR to cut off the Battery Positive connection to protect the inverter against reverse battery polarity. 2) Connection Errors All inputs are protected against connection errors.
  • Page 11 Paragraph (see paragraph 5.1 PASSIVE EMERGENCY CELL). ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions. Furthermore, ZAPI is available to develop new SW or HW solutions to improve the safety of the machine, according to customer requirements.
  • Page 12 separate device and stops the truck distinctly from the Elaboration Unit. This is exactly what the Passive Emergency Cell does. In a system with a single microprocessor technology, the weak point is that just one unit (uC) processes the Inputs and decides alone to keep the motor moving or not.
  • Page 13 6 OPERATIONAL FEATURES Stable speed in every position of the accelerator. Regenerative release braking based upon deceleration ramps. Regenerative braking when the accelerator pedal is partially released (deceleration). Direction inversion with regenerative braking based upon deceleration ramp. Regenerative braking and direction inversion without contactors: only the main contactor is present.
  • Page 14 Electromagnetic susceptibility and emission 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. Therefore ZAPI declines any responsibility for non-compliance if correct testing is not made (the irradiated emission directive is EN50081-2).
  • Page 15 7.4 Main contactor and key connection The connection of the main contactor can be carried out following the drawing in Figure 7–1. An intrinsic protection is present inside the logic when the voltage on the battery power connection overtakes the battery nominal voltage more than a certain percentage.
  • Page 16 8 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.
  • Page 17 8.4 Encoder installation 1) AC1 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 18 9 DESCRIPTION OF THE CONNECTORS Figure 9–1 Page - 18/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual...
  • Page 19 9.1 Connectors of the logic - Standard version with Encoder Figure 9–2 9.1.1 CNA connector Negative of main contactor coil. Positive of main contactor coil NBRAKE Output for driving the electromechanical brake coil; drives the load to -Batt. Maximum current : 3A. Negative of pump contactor coil.
  • Page 20 CPOTB Brake potentiometer wiper. ENC A Encoder Channel A. ENC B Encoder Channel B. 9.1.2 CNB connector Connected to the power supply through a microswitch (KEY) with a 6.3-10A fuse in series (this could be mounted on the AC1 cover). Common of FW / BW / SR1 / SR2 / TILLER / H&S / BELLY / LIFTING / LOWERING microswitches.
  • Page 21 9.2 Connectors of the logic - MDI PRC Version with Encoder Figure 9–3 9.2.1 CNA connector Negative of main contactor coil. Positive of main contactor coil NBRAKE Output for driving the electromechanical brake coil; drives the load to -Batt. Maximum current : 3A. Negative of pump contactor coil.
  • Page 22 CPOTB Proportional electrovalves potentiometer wiper. ENC A Encoder Channel A. ENC B Encoder Channel B. 9.2.2 CNB connector Connected to the power supply through a microswitch (KEY) with a 6.3-10A fuse in series (this can be mounted on the AC1 cover). Common of FW / BW / LIFT AUX / LOW AUX / TILLER / H&S / BELLY / LIFTING / LOWERING microswitches.
  • Page 23 9.3 Description of power connections View of the power bars: Figure 9–4 -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 indication on the motor. AESZP0BA –...
  • Page 24 10 DRAWINGS 10.1 Mechanical drawing Figure 10–1 Page - 24/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual...
  • Page 25 10.2 Connection drawing - Standard version with Encoder Figure 10–2 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 25/73...
  • Page 26 10.3 Connection drawing - MDI-PRC version with Encoder Figure 10–3 Page - 26/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual...
  • Page 27 11 ONE SHOT INSTALLATION PROCEDURE This section of the manual describes the basic connection procedure. The truck needs (to move) a minimum I/O dotation that it is mandatory: this minimum dotation is listed in the Steps from 1 to 8 below. Connect a potentiometer in the range 0.5K to 10Kohms, to modify Step1 the wished speed, between CNB#12, CNB#10, CNB#11.
  • Page 28 When the "Key Switch" is closed, if no alarms or errors are present, the Console Display will be showing the Standard Zapi Opening Display (Home Display). For the setting of your truck, use the procedure below. If you need to reply the same setting on different controller, use the Save and Restore sequence as descripted in the 13.1 and 13.2 paragraphs.
  • Page 29 Can see also the Figure 12–6 for details on the settings. Programming & Adjustments using Digital Console. AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 29/73...
  • Page 30 12 PROGRAMMING &ADJUSTMENTS USING DIGITAL CONSOLE 12.1 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 CNC connector of the inverter. 12.2 Description of console (hand set) & connection Figure 12–1 Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum "Release Number 3.02".
  • Page 31 The section describes the Zapi hand set functions. Numbers inside the triangles correspond to the same number on the hand set keybord buttons shown in the Figure 13–1. The orientation of the triangle indicates the way to the next function.
  • Page 32 12.3.2 MDI PRC Version Figure 12–3 Page - 32/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual...
  • Page 33 12.4 Function configuration We will describe two configurations depending on the MDI-PRC setting (see 12.4.1.15): 1) STANDARD version (MDI-PRC Absent) 2) MDI-PRC version (MDI-PRC Present). In this case the drive control communicates with a MDI-PRC through the CAN BUS. They have different list of settings (the Standard version has a reduced settings list).
  • Page 34 Then roll until the SET OPTION item appears on the hand set display. Push the ENTER button (see Figure 12–4). AC1 ZP 1.00 Opening Zapi Display 24V 250A 00000 Push ROLL UP + SET UP simultaneously to enter...
  • Page 35 2) SET INPUT #1 This setting handles the analog input CNA#13. It can be used one of three: Level 0: CNA#13 is managed as input for an analog motor thermal sensor KTY84-130. Level 1: CNA#13 is managed as a digital cutback speed input (SR#1).
  • Page 36 7) BATTERY CHECK This option specifies the handling of the low battery charge detection. It can be set one of three: Level 0: Nothing happens, the battery charge level is ignored. Level 1: A BATTERY LOW alarm is raised when the battery level is calculated being less than 10% of the full charge.
  • Page 37 Command input for lifting/lowering proportional valves in MDI-PRC version. To turn from the first to the second function is just enough to set PEDAL BRAKING to NONE. This option handles the analog input CNA#18 when used as pedal braking input: ANALOG: With this setting is possible to modulate the strenght of the braking when the accelerator is released.
  • Page 38 14) QUICK INV LOGIC This option specifies the active level for the Belly switch input (CNB#7) OPTION#1: The quick inversion is executed when CNB#7 is closed to a KEY voltage. OPTION#2: The quick inversion is executed when CNB#7 is opened from a KEY voltage.
  • Page 39 The CNA#18 potentiometer modulates the current in the proportional valve connected to the pin#8 of the MDI- PRC. This proportional valve is normally closed (oil does not pass-through when de-energized) and directly connected between the pump and the tank: to do a Lifting function the voltage into the Proportional Valve is turned fully On, to direct the oil into the tank before the pump contactor closes.
  • Page 40 Then roll until the ADJUSTMENTS item appears on the hand set display. Push the ENTER button (see the Figure 12–5 below). AC1 ZAPI V0.0 1) Opening Zapi Menu 24V 250A 00000 2) Press Top Left & Right Buttons to enter % ' %...
  • Page 41 2) SET POT BRK MAX (Standard version only). This setting 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 paragraph 13.3). This procedure must be carried out only if the PEDAL BRAKING option is programmed as ANALOG.
  • Page 42 maximum accelerator position but with two different slope (see also Figure 13–2). 13) THROTTLE Y POINT These parameter, togheter with the THROTTLE X POINT, changes the characteristic of the accelerator input curve (see also paragraph 13.5): when the accelerator is de-pressed to X point per cent, the corresponding truck speed is Y point per cent of the Maximum truck speed.
  • Page 43 20) OPTION 04 (MDI-PRC version only). See OPTION 05. 21) OPTION 03 (MDI-PRC version only). See OPTION 05. 22) OPTION 02 (MDI-PRC version only). See OPTION 05. 23) OPTION 01 (MDI-PRC version only). See OPTION 05. AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 43/73...
  • Page 44 To enter the MAIN MENU’ it is just necessary to push the ENTER button from the home display in the hand set. AC1 ZP 1.00 1) Opening Zapi Menu 24V 250A 00000 ' % ' 2) Press ENTER to go into the General Menu...
  • Page 45 3) INVERS. BRAKING Level 0 to 9. It controls the deceleration ramp when the direction switch is inverted during travel. At Level 9 the truck brakes abrutly. 4) PEDAL BRAKING Level 0 to 9. It controls the deceleration ramp when the travel request is released and the brake pedal switch is pressed to its maximum.
  • Page 46 15) INCHING SPEED (Standard version only because the inching switches are used for the Lifting and Lowering switches in the MDI-PRC version). Hz value. It determines the speed when the "Inching function" is active (see 12.4.1.3-4 SET INPUT#2, SET INPUT#3). 16) INCHING TIME (Standard version only because the inching switches are used for the Lifting and Lowering switches in the MDI-PRC version).
  • Page 47 24V: then it is necessary that the MDI-PRC generates an output voltage with a PWM tecnique never overtaking the 50% Duty Cycle to get the Valve’s voltage less equal than 24V. Through this setting it is possible to take care the voltage on the EVD1 and EVD2 never overcomes the nominal voltage of the valves.
  • Page 48 12.4.3.31 Setting table of the “PARAMETER CHANGE” functions The following table shows the different values at which the parameters can be set. PROGRAMMED LEVEL PARAMETER UNIT ACCELERATION DELAY (*) Sec. 2.05 3.00 3.05 4.00 4.05 5.00 5.05 6.00 6.05 7.00 RELEASE BRAKING (**) Sec.
  • Page 49 12.4.5 Zapi menu “SPECIAL ADJUSTMENTS” functions list Note: the below set-up description is for skilled persons only: if you aren’t please keep your hands off. To enter this Zapi hidden menu a special procedure is required. Ask, this procedure, directly to a Zapi technician.
  • Page 50 6) SLIP VALUE Hz value with two decimal digit. This is the slip between the frequency and the speed of the motor (SLIP VALUE = FREQUENCY-ENCODER). 7) COSFI From 0.00 to 1.00. This is a coarse extimation of the Power Factor (cos f between the voltage and the current in the motor.
  • Page 51 OFF GND= When CNB#8 is not connected to a battery (key) voltage (or it is connected to GND), the Lowering request is not active. 17) FORWARD SWITCH ON/OFF. This is the level of the CNB#6 digital input (Forward Travel demand): ON +VB = When CNB#6 is closed to a battery (key) voltage, the Forward Travel demand is Active.
  • Page 52 QUICK INVERSION reading becomes ON when the Exclusive Hydro Microswitch switch closes and connects the CNB#7 input to a key voltage. 22) CUTBACK SWITCH 2 (Standard version only). ON/OFF. This is the level of the CNA#14 digital input (When the MDI-PRC is not present, and SET INPUT #2 is set PRESENT, this is the Speed Reduction #2 request): ON GND = When CNA#14 is not closed to a battery (key) voltage (or...
  • Page 53 OFF GND = When CNA#15 is not closed to a battery (key) voltage (or it is connected to GND) the Aux Lowering request is not active. AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 53/73...
  • Page 54 - 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. AC1 ZAPI V0.0 Opening Zapi Display 24V 250A 00000 ' % '...
  • Page 55 ' ' ' Press OUT to return to the Opening Zapi Display ' % ' NOTE: in reality the SAVE and RESTORE function requires the Windows PC- Console. 13.2 Description of console “RESTORE” function The RESTORE PARAM function allows transfer of the Console’s stored data into the memory of the chopper.
  • Page 56 MAIN MENU When finished, the Console shows : RESTORE PARAM. ' ' ' Press OUT to return to the Opening Zapi Display ' % ' NOTE: in reality the SAVE and RESTORE function requires the Windows PC- Console. 13.3 Description of console “PROGRAM VACC” function This enables adjustment of the minimum and maximum useful signal level, in either direction.
  • Page 57 ' % ' MAIN MENU When finished, the Console shows : PROGRAM VACC ' ' ' Press OUT to return to the Opening Zapi Display ' % ' AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 57/73...
  • Page 58 13.4 Shortform table of the aux output #1 setting The AUX OUTPUT #1 setting specifies the handling of the CNA#3 output and the STOP ON RAMP service (when the encoder is used). This handling is summarized in the table below. STOP ON A3 OUTPUT BEHAVIOUR ON A SLOPE...
  • Page 59 13.5 Description of the throttle regulation This regulation applies a not linear relationship between the position of the accelerator and the speed of the truck. The main goal is to increase the resolution for the speed modulation when the truck is slow moving. Three ajustments are used for the throttle regulation: 1) THROTTLE 0 ZONE 2) THROTTLE X POINT...
  • Page 60 13.6 Description of the battery charge detection setting The Battery Charge detection uses two setting that specify the Full Charge Voltage Level (100%) and the Discharge Voltage Level (10%). These two settings are the ADJUSTMENT#01 and the ADJUSTMENT#02 (see 12.4.2.14 and 12.4.2.15).
  • Page 61 Try to execute a CLEAR EEPROM operation. This consists of Entering the ALARMS item in the MAIN MENU’. Push at the same time the two right side buttons to enter the hidden ZAPI MENU’. Roll up and Down until the CLEAR EEPROM appears on the hand set display.
  • Page 62 (e.g. when the pump inrush current makes the battery temporary collapsed). So first of all check for your failure mode then contact the Zapi technician to look for a countermeasure. As a matter of fact this alarm may occurs also for a HW failure and, in this case, it is necessary to substituite the Controller.
  • Page 63 - Remedy: Check the handbrake switch and its wiring to CNA#13. The handbrake switch must be connected between CAN#13 and GND voltage. When it is closed to GND the handbrake is considered active. A failure in the logic is possible too. In this case it is necessary to substituite the controller.
  • Page 64 - A Power failure or a Logic Failure occured in the controller. In this case it is necessary to substituite the controller. 2) VMN HIGH MDI-PRC Code = 31 - Cause: Before to switch the main contactor on, the SW turns on sequencely the Bottom side Power Mosfets and expects the phase V voltage falls to GND value.
  • Page 65 with the potentiometer: if the potentiometer gets disconnected on PPOT or NPOT, no current flow in this sense diode and the voltage on the NPOT connection collapses down. When the NPOT voltage is less than 0.3V this alarm occurs. This alarm occurs also when the NPOT voltage is higher than 2Vdc (to detect also the condition of a broken sense diode).
  • Page 66 2) STBY I HIGH MDI-PRC Code = 53 - Cause: This diagnosis is executed only when the main contactor is opened and asked to be closed (e.g. at key on or when the main contactor is opened and a new motion request turns active).
  • Page 67 the Driver of the Elecromechanical Brake is short circuited) and this alarm occurs. b) When the feedforward PWM is higher than 70% of the battery voltage, the Actual voltage on the Electromechanical Brake is expected high. If it is lower than 14V it means the Electromechanical Brake always gets the truck Braked (probably the Driver of the Elecromechanical Brake is opened) and this alarm occurs.
  • Page 68 than 400msec. The goal of this diagnosis is to detect a failure of the A/D converter or a problem in the code flow that omits the refreshing of the analog signal conversion. - Remedy: If the problem occurs permanently it is necessary to substituite the controller.
  • Page 69 Then it is necessary to specify if the controller is AC0 or AC1 type (see AC TYPE 0 in the hidden hardware setting Zapi menu). If the alarm is present, by switching off the key the AC TYPE 0 setting will be turned automatically On (and the controller is specified to be an AC0).
  • Page 70 14.2 MDI-PRC “ALARMS” List When the Controller communicates with the MDI-PRC, the alarm condition is represented on the MDI-PRC in a Numeric form is: Source Device Code and Alarm Code. The Source Device Code we are interesting in are: This is a local MDI-PRC alarm This is a Traction Controller (AC1) alarm The Alarm Code List Sourced by the Controller (Source Device Code 02) is the following:...
  • Page 71 MDI DRV2 SHORT At least one On/Off driver on pin#4 and #6 is shorted MDI DRV2 OPEN At least one On/Off driver on pin#4 and #6 is opened MDI PEV NOT OK The Positive Supply for the Valves is missing MDI NEVP1 NOT OK At least one Proportional Valve driver on pin#8 and #9 is shorted...
  • Page 72 15 RECOMMENDED SPARE PARTS Part number Description C29508 SW 180 24V Single Pole Contactor Page - 72/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual...
  • Page 73 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.