Zapi COMBI AC1 User Manual
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Zapi COMBI AC1 User Manual

Zapi COMBI AC1 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
User Manual
COMBI AC1

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Summary of Contents for Zapi COMBI AC1

  • 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 User Manual COMBI AC1...
  • 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: Table Of Contents

    Mechanical drawing ....................29 Connection drawing ....................30 7.2.1 AmpSaab version..................30 7.2.2 AmpSeal version..................31 ONE SHOT INSTALLATION PROCEDURE...............32 Sequence for Ac Inverter traction setting..............33 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE........35 Adjustments via console ...................35 AEQZP0BA – COMBI AC1 - User Manual Page - 3/86...
  • Page 4 Description of console “PROGRAM VACC” function..........59 10.4 Description of the throttle regulation................. 61 10.5 Description of the battery charge detection setting ..........62 11 COMBI AC1 ALARMS LIST ....................64 11.1 Faults diagnostic system ..................64 11.2 Master microcontroller alarms overview ..............65 11.3...
  • Page 5 APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN GRAPHIC AND LAYOUT PROJECT MANAGER TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Publication N°: AEQZP0BA Edition: August 2005 AEQZP0BA – COMBI AC1 - User Manual Page - 5/86...

  • Page 6: Introduction

    1 INTRODUCTION The COMBI AC1 inverter has been developed to perform all the electric functions that are usually presents in walkie trucks, stackers, low order pickers etc. The controller can perform the following functions: Controller for Ac 700W to 3.5Kw AC motors;...

  • Page 7: Specification

    Dc chopper Maximum current (36V, 48V):..........300A for 2’ Chopper Operating frequency:..............16kHz External temperature working range: ..........-40°C ÷ 40°C Maximum heatsink temperature (start of the thermal cutback) ....... 85°C 2.2 Block diagrams AEQZP0BA – COMBI AC1 - User Manual Page - 7/86...

  • Page 8: Specification For The Input Devices Filling Up The Installation Kit

    3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 3.1 Digital inputs Combi Ac1 digital inputs work in the voltage range [-B; +B]. Related command devices (microswitches) must be connected to +B (typically to key voltage). Pull-down resistance to –B is built-in.

  • Page 9: Analog Unit

    3.2 Analog unit The analog input can be connected to an accelerator unit if the Zapi can or serial tiller is not used. The accelerator unit can consist of a potentiometer or an Hall effect device. It should be in a 3-wire configuration. The potentiometer is supplied through CNA#26 [AmpSaab connector] OR CNA#25 [Ampseal connector].

  • Page 10: Analog Motor Thermal Sensor Input

    - power supply: +12V - electric output: open collector ( NPN or PNP), push-pull. COMBI AC1 could also be used without encoder, sensorless control. This solution has to be discussed with Zapi technicians. Note: The encoder resolution and the motor poles pair (the controller can...

  • Page 11: Installation Hints

    AEQZP0BA – COMBI AC1 - User Manual Page - 11/86...

  • Page 12: Fuses

    It is necessary to ensure that cold air is taken from outside the controller compartment and hot air is easily pushed away from the controller compartment. It is mandatory to avoid that the cooling air is recirculated inside the controller compartment. Page - 12/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 13: Wirings: Power Cables

    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. AEQZP0BA – COMBI AC1 - User Manual Page - 13/86...
  • Page 14 Note: Module 1 power > Module 2 power > Module 3 power The chain starts from the –BATT post of the controller that works with the highest current, and the others are connected in a decreasing order of power. Page - 14/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 15: Wirings: I/O Connections

    “description of the connectors” AEQZP0BA – COMBI AC1 - User Manual Page - 15/86...

  • Page 16: Connection Of The Encoder

    4.2.5 Connection of the encoder 1) COMBI 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 17: Main Contactor And Key Connection

    It is necessary to specify in the order the type of encoder used, in terms of power supply, electronic output and n° of pulses for revolution, because the logic unit must be set in the correct way by Zapi. The n° of pulses revolution the controller can handle is given by the second-last letter in the software release name (see 3.5).

  • Page 18: Insulation Of Truck Frame

    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. Page - 18/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 19: Protection And Safety Features

    4.3 Protection and safety features 4.3.1 Protection features The COMBI AC1 is protected against some controller injuries and malfunctions: Battery polarity inversion It is necessary to fit a LINE CONTACTOR to protect the controller against reverse battery polarity and for safety reasons.

  • Page 20: Safety Features

    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 21 ELECTROMAGNETIC IMMUNITY. The considerations made for emissions are valid also for immunity. Additionally, fu rther protection can be achieved with ferrite beads and bypass capacitors. AEQZP0BA – COMBI AC1 - User Manual Page - 21/86...

  • Page 22: Various Suggestions

    4.5 Various suggestions Never combine SCR low frequency choppers with COMBI AC1 modules. The filter capacitors contained in the COMBI AC1 module would change the SCR chopper operation and subject to excessive workload. If it is necessary to use two or more control units, like the chopper should both be of the Zapimos family.

  • Page 23: Operational Features

    Error codes are provided in two ways. The digital console can be used, which gives a detailed information about the failure; the failure code is also sent on the Can-Bus. AEQZP0BA – COMBI AC1 - User Manual Page - 23/86...

  • Page 24: Description Of The Connectors

    6 DESCRIPTION OF THE CONNECTORS 6.1 Connectors of the logic AmpSaab version Page - 24/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 25: Cna Connector: Ampsaab Version

    Output of the electrovalve 2 driver (driving to –Batt) NEV3 Output of the electrovalve 3 driver (driving to –Batt) Output of the Line Contactor coil driver (driving to – Batt) AEQZP0BA – COMBI AC1 - User Manual Page - 25/86...

  • Page 26: Cna Connector: Ampseal Version

    Negative of the Encoder CUTBACK Speed reduction switch input #1. Active low (switch opened). BELLY Quick inversion function input, must be connected to the belly microswitch. It is active high (+VB). Page - 26/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 27 Forward switch input, active high (+VB). NEV3 Output of the electrovalve 3 driver (driving to –Batt). NEV4 Output of the electrovalve 4 driver (driving to –Batt). Input of the switch DIGITAL INPUT #7. AEQZP0BA – COMBI AC1 - User Manual Page - 27/86...

  • Page 28: Description Of Power Connections

    Positive of the battery, before the fuse. Output of the Pump Motor. U; V; W Connection bars of the three motor phases; follow this sequence and the indication on the motor. Page - 28/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 29: Drawings

    7 DRAWINGS 7.1 Mechanical drawing AEQZP0BA – COMBI AC1 - User Manual Page - 29/86...

  • Page 30: Connection Drawing

    7.2 Connection drawing 7.2.1 AmpSaab version Page - 30/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 31: Ampseal Version

    7.2.2 AmpSeal version AEQZP0BA – COMBI AC1 - User Manual Page - 31/86...

  • Page 32: One Shot Installation Procedure

    The Steps from 1 to 8 describe the installation operations that is mandatory to do in order your truck moves. Obviously the COMBI AC1 may execute a wider set of optional services as:...

  • Page 33: Sequence For Ac Inverter Traction Setting

    The index may help you. 8.1 Sequence for Ac Inverter traction setting This section of the manual describes the basic COMBI AC1 set-up procedure using the hand-set: 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).
  • Page 34 Make the choice for the truck behaviour on a slope. If the "Stop on Step15 ramp" option is ON, set the desired value of "auxiliary time" parameter. Page - 34/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 35: Programming & Adjustments Using Digital Console

    Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum Release Number: 3.02. The section describes the Zapi hand set functions. Numbers inside the triangles correspond to the same number on the hand set keyboard buttons shown in the figure.

  • Page 36: Description Of The Console Menu

    9.3 Description of the console menu 9.3.1 Master: AmpSaab version Page - 36/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 37: Master: Ampseal Version

    9.3.2 Master: AmpSeal version AEQZP0BA – COMBI AC1 - User Manual Page - 37/86...

  • Page 38: Slave: Ampsaab Version

    9.3.3 Slave: AmpSaab version Page - 38/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 39: Slave: Ampseal Version

    9.3.4 Slave: AmpSeal version AEQZP0BA – COMBI AC1 - User Manual Page - 39/86...

  • Page 40: Function Configuration (Master)

    ' % ' 1) TILLER SWITCH This option handles the input CNA#7 in AmpSaab [CNA#1 in AmpSeal]. This input opens when the operator leaves the truck (tiller released). It is Page - 40/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 41 EX.HYDRO: it drives the contactor for a hydraulic steering function when the exclusive hydro input is active FREE: it is not used. The current this output can sink is up to 3Adc. 6) QUICK INVERSION It can be set: AEQZP0BA – COMBI AC1 - User Manual Page - 41/86...

  • Page 42: Config Menu "Adjustments" Functions List

    % ' ' TROTTLE 0 ZONE 9) The desired parameter appears 10) Press SET UP or SET DOWN button to modify ' ' % ' ' % the adjustment Page - 42/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 43 Turn it On when the required Maintenance service has been executed to cancel the CHECK UP NEEDED warning. 10) CHECK UP TYPE It specifies the handling of the CHECK UP NEEDED warning: AEQZP0BA – COMBI AC1 - User Manual Page - 43/86...

  • Page 44: Main Menu "Parameter Change" Functions List

    ARE YOU SURE? 11) The Display asks: “ARE YOU SURE?” YES=ENTER NO=OUT 12) Press ENTER to accept the changes, or press ' ' ' ' % ' OUT to discard them. Page - 44/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 45 Typically from 10% to 100%. It determines the percentage of the max speed applied when the cutback switch 2 is active. When set to 100% the speed reduction is ineffective. AEQZP0BA – COMBI AC1 - User Manual Page - 45/86...
  • Page 46 23) AUXILIARY TIME Time units value (seconds). For the encoder version, it determines the time duration the truck is hold on the ramp if the STOP ON RAMP option is ON. Page - 46/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 47: Zapi Menu "Special Adjustments" Functions List

    9.4.4 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 for this procedure, directly to a Zapi technician.

  • Page 48: Main Menu "Tester" Functions List

    4) HIGH ADDRESS To be used to have access to special memory address. NOTE: only Zapi technicians should change this value 9.4.5 Main menu “TESTER” functions list The TESTER functions are a real time feedback measurements of the state of the controller/motor/command devices.
  • Page 49 GND), the Forward Travel demand is not active. 17) BACKWARD SWITCH ON/OFF. This is the level of the digital input CNA#19 in AmpSaab connector [CNA#31 in Ampseal connector] for the backward travel demand: AEQZP0BA – COMBI AC1 - User Manual Page - 49/86...
  • Page 50 ON +VB = When is closed to a battery (key) voltage, the Lifting request is Active. OFF GND = When is not connected to a battery (key) voltage (or it is connected to GND), the Lifting request is not active. 24) LIFTING CUTOUT Page - 50/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 51: Function Configuration (Slave)

    THROTTLE 0 ZONE and the X point and also between the X point and the maximum accelerator position but with two different slope. AEQZP0BA – COMBI AC1 - User Manual Page - 51/86...

  • Page 52: Config Menu "Parameter Change" Functions List

    Adjustment of the compensation function when the pump motor steering function is active. 9) CUTBACK SPEED Percentage of the maximum speed. It defines the reduction of the pump motor speed when the cutback is triggered. Page - 52/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 53 From 0 to 25.5 sec., resolution of 0.1 EV1 OPEN DELAY Sec. From 0 to 25.5 sec., resolution of 0.1 EV1 CLOSE DELAY Sec. From 0 to 25.5 sec., resolution of 0.1 AEQZP0BA – COMBI AC1 - User Manual Page - 53/86...

  • Page 54: Config Menu "Special Adjustments " Functions List

    1) ADJUSTMENT #1 (Factory adjusted). % value. This is the Gain of the Pump chopper Current Sensing Amplifier. NOTE: only Zapi technicians should change this value. 2) SET CURRENT set the current limit for the measurement in the TESTER menu.

  • Page 55: Config Menu "Tester " Functions List

    On/off : it determines if the input 4 is active or not (Reverse switch, CNA#19 in AmpSaab, CNA#31 in AmpSeal). 13) DIGITAL INPUT 5 On/off : it determines if the input 5 is active or not (CNA#20 in AmpSaab, CNA#19 in AmpSeal). AEQZP0BA – COMBI AC1 - User Manual Page - 55/86...
  • Page 56 On/off: determines if the valve is open or closed. 25) EV6 On/off: determines if the valve is open or closed. 26) EV7 On/off: determines if the valve is open or closed. Page - 56/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 57: Other Functions

    You can see the items that are being stored whilst READING … ACCEL. DELAY (ECC.) the SAVE routine is happening SELECT: MOD. 01 When finished, the Console shows : FREE AEQZP0BA – COMBI AC1 - User Manual Page - 57/86...

  • Page 58: Description Of Console "Restore" Function

    ' ' ' Press OUT to return to the Opening Zapi Display ' % ' NOTE: in reality the SAVE and RESTORE function requires the Windows PC- Console. 10.2 Description of console “RESTORE” function The RESTORE PARAM function allows transfer of the Console’s stored data into the memory of the controller.

  • Page 59: Description Of Console "Program Vacc" Function

    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. 10.3 Description of console “PROGRAM VACC” function This enables adjustment of the minimum and maximum useful signal level, in either direction.
  • Page 60 Press ENTER for yes, or OUT for NO ' % ' MAIN MENU When finished, the Console shows : PROGRAM VACC ' ' ' Press OUT to return to the Opening Zapi Display ' % ' Page - 60/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 61: Description Of The Throttle Regulation

    (see figure below) to match the full speed in the truck with the MAX VACC voltage in the accelerator position. AEQZP0BA – COMBI AC1 - User Manual Page - 61/86...

  • Page 62: Description Of The Battery Charge Detection Setting

    (e.g. if the Battery Discharged Detection occurs when the battery is not totally discharged, it is necessary to reduce the Bat.Min.Adj setting as indicated in the figure below). 48V NOMINAL BATTERY VOLTAGE 24V NOMINAL BATTERY VOLTAGE Page - 62/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 63 5) After key on battery charge can be only increased if the battery charge computed after key on is greater than the last value stored in Eeprom the battery charge value is updated otherwise the Battery charge is not updated. AEQZP0BA – COMBI AC1 - User Manual Page - 63/86...

  • Page 64: Combi Ac1 Alarms List

    These warnings are related to: - wrong operator sequences - conditions which require performance reduction (like high temperatures, ….) Page - 64/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 65: Master Microcontroller Alarms Overview

    Eb applied Safety Waiting for trac Master uC has detected a problem on the feedback of Valve, pump, traction stopped, Lc continuous Key re-cycle Feedback EVP driver opened, Eb applied AEQZP0BA – COMBI AC1 - User Manual Page - 65/86...

  • Page 66: Analysis And Troubleshooting Of Master Microcontroller Alarms

    B) If the alarm occurs during motor running, check: Motor connections If motor phases windings/cables have leakages towards truck frame That the LC power contact closer properly, with a good contact Page - 66/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 67 B) In case no failures/problems have been found externally, the problem is in the controller, which has to be replaced. 7) “DRIVER SHORTED” Cause: AEQZP0BA – COMBI AC1 - User Manual Page - 67/86...
  • Page 68 Troubleshooting: A) It is suggested to check the harness, in order to verify if a positive is connected to the Smart driver output (CNA#30 AmpSaab connector, CNA#2 AmpSeal connector) Page - 68/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 69 This type of fault is not related to external components so, when it is present, it is necessary to replace the controller. 18) “WRONG SET BATTERY” Cause: At start-up, the controller checks the battery voltage and verify it is within a AEQZP0BA – COMBI AC1 - User Manual Page - 69/86...
  • Page 70 Otherwise it is an internal fault of the controller which must be replaced. 23) “HARDWARE FAULT” Cause: The master microcontroller has detected that the slave microcontroller is not able to stop the traction enable or LC-EB enable. Page - 70/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 71 This is a safety related test. Master µC has detected a problem on the feedback of EVP driver. Troubleshooting: This is a internal fault of the controller, it is necessary to replace it. AEQZP0BA – COMBI AC1 - User Manual Page - 71/86...

  • Page 72: Master Warnings Overview

    Waiting for Slave uC is in alarm condition, Master continuous node uC is waiting for it to resolve its error condition Page - 72/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 73: Analysis And Troubleshooting Of Master Warnings

    This alarm occurs when the temperature of the base plate is higher than 85°. Then the maximum current decreases proportionally with the temperature increases from 85° up to 105°. At 105° the Current is limited to 0 Amps. AEQZP0BA – COMBI AC1 - User Manual Page - 73/86...
  • Page 74 This is just a warning to call for the time programmed maintenance. Troubleshooting: It is just enough to turn the CHECK UP DONE option to level ON after the maintenance is executed. 12) “DATA ACQUISITION” Cause: Acquisition of the current gains. Page - 74/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 75 The Maximum current gain parameters are at the default values, which means the maximum current adjustment procedure has not been carried out yet. Troubleshooting: Ask the assistance of a Zapi technician to do the correct adjustment procedure of the current gain parameters. 16) “WAITING FOR NODE” Cause: The controller receives from the CAN the message that another controller in the net is in fault condition;...

  • Page 76: Slave Alarms Overview

    Slave uC has detected that Master uC is not valve, pump, traction start-up (EVP Key re-cycle Node able to stop hydraulic functions stopped, Lc opened, related test) Eb applied stby (pump chopper related test) Page - 76/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 77: Analysis And Troubleshooting Of Slave Alarms

    Troubleshooting: If the problem occurs permanently it is necessary to substitute the controller. 5) “LOGIC FAILURE #1” Cause: This fault is displayed when the controller detects an overvoltage or AEQZP0BA – COMBI AC1 - User Manual Page - 77/86...
  • Page 78 This is a safety related test. Slave µC has detected a mismatch between its input (digital, analog and encoder) and correspondant Master µC inputs. Troubleshooting: This is a internal fault of the controller, it is necessary to replace it. Page - 78/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 79 Cause: The slave has detected that the master microcontroller is not able to stop hydraulic functions. Troubleshooting: This type of fault is not related to external components; replace the controller. AEQZP0BA – COMBI AC1 - User Manual Page - 79/86...

  • Page 80: Slave Warnings Overview

    100% the current is maximum current reduced lineary from 85°c to 105°C reduced proportionally to T increase reduction by Pump Warning Master requests a reduction pump speed reduced continuous master Page - 80/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 81: Analysis And Troubleshooting Of Slave Warnings

    In standby condition (pump motor not driven), the feedback coming from the current sensor in the pump chopper gives a value too high (>0,8). Troubleshooting: This type of fault is not related to external components; replace the controller. AEQZP0BA – COMBI AC1 - User Manual Page - 81/86...
  • Page 82 Lift/Lower accelerator is released. Troubleshooting: Check the mechanical calibration and the functionality of the potentiometer. 13) “RAM WARNING” Cause: Checksum of the ram failed. Troubleshooting: This fault is not related to external components. Page - 82/86 AEQZP0BA – COMBI AC1 - User Manual...
  • Page 83 Improve the air cooling of the controller. If the alarm is signaled when the controller is cold, the possible reasons are a thermal sensor failure or a failure in the logic card. In this case, it is necessary to replace the controller. AEQZP0BA – COMBI AC1 - User Manual Page - 83/86...
  • Page 84 19) “REDUCTION BY MASTER” Cause: The master has requested a reduction of performance of the slave. Troubleshooting: Check in the master the cause of the reduction. Page - 84/86 AEQZP0BA – COMBI AC1 - User Manual...

  • Page 85: Recommended Spare Parts

    12 RECOMMENDED SPARE PARTS Part number Description FUSE PROT. 425A INTERAS60 C16506 (for 24v and 48v version) AMPSAAB CONNECTOR C12505 42 pins Female AMPSEAL CONNECTOR C12532 35 pins Female AEQZP0BA – COMBI AC1 - User Manual Page - 85/86...

  • Page 86: 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.

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