Zapi AC-2 User Manual
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Zapi AC-2 User Manual

Zapi AC-2 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
AC-2
INVERTER

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Summary of Contents for Zapi AC-2

  • 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 AC-2 INVERTER...
  • Page 2 The symbol aboard is used inside this publication to indicate an action or a characteristic very important as for security. Pay special attention to the annotations pointed out with this symbol. Page - 2/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 3: Table Of Contents

    Sequence for Ac Inverter Pump setting ..............43 5.10 Tester: description of the function; Traction configuration ........43 5.11 Tester: description of the function; Pump configuration..........45 OTHER FUNCTIONS ......................48 Description of the Console “SAVE” function .............48 ADEZP0AE - AC-2 INVERTER - User Manual Page - 3/64...
  • Page 4 Description of Console “RESTORE” function ............50 Description of “ALARMS” menu ................52 Description of Console “PROGRAM VACC” function..........53 AC-2 INVERTER DIAGNOSTIC - TRACTION CONFIGURATION ........55 Analysis of alarms displayed on console..............55 AC-2 INVERTER DIAGNOSTIC - PUMP CONFIGURATION..........59 Analysis of alarms displayed on console..............

  • Page 5: Introduction

    1 INTRODUCTION Within the ZAPIMOS family, the AC-2 inverter is the model suitable for control of 3.0 kW to 8.0 kW motors. It has been expressly designed for battery electric traction. It is fit for electric truck, golf cars, utility cars.

  • Page 6: Specification

    100 µA. When full load connected, the voltage drop between the key switch contacts must be lower than 0.1 V. The microswitches send a voltage signal to the microprocessor when a Page - 6/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 7: Accelerator Unit

    The CPOTB (E8) signal range is from 0 to 10 V. 2) Connections F6 (PTHERM) and F12 (NTHERM) are used for a motor thermal sensor. It can be digital (on/off sensor, normally closed) or analog. See also ADEZP0AE - AC-2 INVERTER - User Manual Page - 7/64...

  • Page 8: Speed Feedback

    (the machine is electrically hold on a slope) for a programmable time (see also chapter 5.4). Stable speed in every position of the accelerator. Page - 8/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 9: Diagnosis

    Diagnosis is 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. ADEZP0AE - AC-2 INVERTER - User Manual Page - 9/64...

  • Page 10: Thermal Consideration

    If a mechanical battery line switch is installed, it is necessary that the key supply to the inverter is open together with power battery line; if not, the inverter may be damaged if the switch is opened during a regenerative braking. Page - 10/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 11 An intrinsic protection is present inside the logic when the voltage on the battery power connection overtakes 40% more than the battery nominal voltage or if the key is switched off before the battery power line is disconnected. ADEZP0AE - AC-2 INVERTER - User Manual Page - 11/64...

  • Page 12: Usafety And Protection

    The safety of the machine is strongly related to installation; length, layout and screening of electrical connections have to be carefully designed. AC-2 inverter electronic implements an hardware safety circuit, which is able to open the Line Contactor (LC) and the Electric Brake (EB) - and therefore to cut the power line stopping the machine via HARDWARE, that is bypassing the software control of the LC and EB.

  • Page 13: Installation

    For special applications or requirements these values can be reduced. For Safety reasons, we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow. ADEZP0AE - AC-2 INVERTER - User Manual Page - 13/64...

  • Page 14: Description Of Connectors - Traction Configuration

    It must be connected to A7 for the Flash memory programming (if used). -BATT -Batt. MODE This input allows the customer to select the software for traction or lifting application. Page - 14/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 15 SEAT input; it must be connected to the SEAT microswitch; it is active high. SAFETY If not connected to -Batt the MC coil power output will be disabled. It can also be used as a general purpose ADEZP0AE - AC-2 INVERTER - User Manual Page - 15/64...

  • Page 16: Description Of Connectors - Pump Configuration

    -Batt maximum current: 3 A. SR/HB Speed reduction (handbrake) input. Active low (switch opened). See also OPTION chapter. -Batt. NTHERM -Batt. 4.5 Description of connectors - Pump configuration Page - 16/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 17 Input for hydraulic steering request. Active high. Speed reduction input. Active low (switch opened). DIG. IN. This is a digital input, free for customer request. Connected to the power supply through a microswitch ADEZP0AE - AC-2 INVERTER - User Manual Page - 17/64...

  • Page 18: Encoder Installation

    -Batt. 4.6 Encoder installation 1) AC-2 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 +12 V. It can have different electronic output.
  • Page 19 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. ADEZP0AE - AC-2 INVERTER - User Manual Page - 19/64...

  • Page 20: 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 indication on the motor. Page - 20/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 21: Mechanical Drawing

    4.8 Mechanical drawing ADEZP0AE - AC-2 INVERTER - User Manual Page - 21/64...

  • Page 22: Connection Drawing - Traction Configuration

    4.9 Connection drawing - Traction configuration Page - 22/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 23: Connection Drawing - Pump Configuration

    4.10 Connection drawing - Pump configuration ADEZP0AE - AC-2 INVERTER - User Manual Page - 23/64...

  • Page 24: Connection Drawing - Combi Configuration

    4.11 Connection drawing - Combi configuration Page - 24/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 25: Programming & Adjustments Using Digital Console

    Digital Console. The Console is connected to the “A” 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". ADEZP0AE - AC-2 INVERTER - User Manual Page - 25/64...

  • Page 26: Description Of Standard Console Menu

    5.3 Description of Standard Console Menu 5.3.1 Traction configuration Page - 26/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 27: Pump Configuration

    5.3.2 Pump configuration 5.4 Function configuration 5.4.1 Traction Using the CONFIG MENU of the programming console, the user can configure ADEZP0AE - AC-2 INVERTER - User Manual Page - 27/64...
  • Page 28 (brake switch closed), the inverter performs an electrical braking following "Pedal braking" parameter. 8) SET TEMPERATURE DIGITAL: a digital (ON/OFF) motor thermal sensor is connected to F6 input. Page - 28/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 29 This parameter changes the characteristic of the accelerator input curve. 7) THROTTLE Y POINT This parameter changes the characteristic of the accelerator input curve. VACC MIN and VACC MAX are values programmable by the "Program ADEZP0AE - AC-2 INVERTER - User Manual Page - 29/64...
  • Page 30 13) CHECK UP DONE For an explanation of this point see the MDI instrument handbook. 14) CHECK UP TYPE For an explanation of this point see the MDI instrument handbook. Page - 30/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 31: Pump

    10%, an alarm is signalled and the maximum current is reduced to the half of the programmed value. ADEZP0AE - AC-2 INVERTER - User Manual Page - 31/64...
  • Page 32 This parameter determines the motor temperature level at which the “Motor temperature” alarm is signalled. The range is from 70 °C to 160 °C with 10 °C steps. This parameter must be adjusted only if the “Set temperature” (menu Page - 32/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 33 It adjusts the lower level of the battery discharge table. 9) ADJUSTMENT #01 It adjusts the upper level of the battery discharge table. 10) LOAD HM FROM MDI For an explanation of this point see the MDI instrument handbook. ADEZP0AE - AC-2 INVERTER - User Manual Page - 33/64...
  • Page 34 OUT if you do not accept the changes. CONFIG MENU 15) SET OPTIONS Menu appears. SET OPTIONS 16) Press OUT again. Display now show the ' ' ' ' % ' Opening Zapi Menu. Page - 34/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 35 11) Press OUT. ' % ' ' % ' 12) Press ENTER to confirm. ' ' ' 13) Repeat the same from 5 to 12 points for the other adjustments. ADEZP0AE - AC-2 INVERTER - User Manual Page - 35/64...
  • Page 36 ' ' ' ' % ' OUT if you do not accept the changes. 13) Press OUT. Display now shows the Opening ' ' ' ' % ' Zapi Menu. Page - 36/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 37 OUT if you do not accept the changes. CONFIG MENU 15) ADJUSTMENTS Menu appears. ADJUSTMENTS 16) Press OUT. Display now show the Opening ' ' ' ' % ' Zapi Menu. ADEZP0AE - AC-2 INVERTER - User Manual Page - 37/64...

  • Page 38: Parameter Regulation: Traction Configuration

    It determines the time that the truck is hold on the ramp if the "stop on ramp" option is ON. The following table shows the different values at which the parameters can be set. Page - 38/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 39: Parameter Regulation: Pump Configuration

    It determines the maximum lifting speed with a potentiometer control. 4) MIN SPEED UP It determines the minimum lifting speed with a potentiometer control when the lifting enable switch is closed. ADEZP0AE - AC-2 INVERTER - User Manual Page - 39/64...
  • Page 40 Parameters modified and optimized on one unit can be stored by the console (SAVE) and then released (RESTORE) on another inverter, thus allowing fast and standardized settings (see console manual for details). Page - 40/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 41: Programming Console Functions

    Functional configuration (see 5.1, 5.2, 5.3, 5.4). Parameter programming (see 5.5, 5.6). Tester: the user can verify the state of the following parameters: TRACTION PUMP motor voltage (%) motor voltage (%) frequency (Hz) frequency (Hz) ADEZP0AE - AC-2 INVERTER - User Manual Page - 41/64...

  • Page 42: Sequence For Ac Inverter Traction Setting

    Increase the Level accordingly. 8) Set the Speed Reductions as required. Make adjustments to “CUTBACK SPEED” Check the performance with the accelerator pedal totally depressed. Page - 42/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 43: Sequence For Ac Inverter Pump Setting

    5.10 Tester: description of the function; Traction configuration The most important input or output signals can be measured in real time using the TESTER function of the console. The Console acts as a multimeter able to ADEZP0AE - AC-2 INVERTER - User Manual Page - 43/64...
  • Page 44 OFF / GND = non active entry of open switch. 15) CUTBACK SWITCH The level of the Speed Reduction Microswitch. ON / GND = active entry of speed reduction microswitch. OFF / +VB = non active entry of microswitch. Page - 44/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 45: Tester: Description Of The Function; Pump Configuration

    The voltage of the accelerator potentiometer's wiper (CPOT). The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side. ADEZP0AE - AC-2 INVERTER - User Manual Page - 45/64...
  • Page 46 17) BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch. 18) BATTERY CHARGE The percentage Charge level of the battery. Page - 46/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 47 ' % ' Display. MAIN MENU TESTER Remember it is not possible to make any changes using TESTER. All you can do is measure as if you were using a pre-connected multimeter. ADEZP0AE - AC-2 INVERTER - User Manual Page - 47/64...

  • Page 48: Other Functions

    10) You can see the items that are being stored READING … ACCEL. DELAY (ECC.) whilst the SAVE routine is happening. MAIN MENU 11) When finished, the Console shows: SAVE PARAM Page - 48/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 49 12) Press OUT to return to the Opening Zapi ' ' ' ' % ' Display. ADEZP0AE - AC-2 INVERTER - User Manual Page - 49/64...

  • Page 50: Description Of Console "Restore" Function

    10) The Display will ask “ARE YOU SURE?”. ARE YOU SURE? YES=ENTER NO=OUT ' % ' ' ' ' 11) Press ENTER for YES, or OUT for No. ' ' ' ' % ' Page - 50/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 51 RESTORE routine is ACCELER. DELAY happening. MAIN MENU 13) When finished the Console displays: RESTORE PARAM. 14) Press OUT to return to the Opening Zapi ' ' ' ' % ' Display. ADEZP0AE - AC-2 INVERTER - User Manual Page - 51/64...

  • Page 52: Description Of "Alarms" Menu

    12) Press ENTER for yes, or OUT for NO. ' ' ' ' % ' 13) Press OUT to return to the Opening Zapi ' ' ' ' % ' Display. Page - 52/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 53: Description Of Console "Program Vacc" Function

    ' % ' ARE YOU SURE 13) The Display will ask: “ARE YOU SURE”?. YES=ENTER NO=OUT ' % ' 14) Press ENTER for yes, or OUT for NO. ' % ' ADEZP0AE - AC-2 INVERTER - User Manual Page - 53/64...
  • Page 54 MAIN MENU 15) When finished, the Console shows: PROGRAM VACC 16) Press OUT again to return to the Opening Zapi ' ' ' ' % ' Menu. Page - 54/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 55: Inverter Diagnostic - Traction Configuration

    Two possible reasons: A) A real undervoltage / overvoltage situation happened. B) Fault in the hardware section of the logic board which manages the overvoltage protection. Replace the logic card. ADEZP0AE - AC-2 INVERTER - User Manual Page - 55/64...
  • Page 56 If this is not true: an alarm is signalled; the main contactor is not closed. Possible reasons: Page - 56/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 57 The main contactor coil has been driven by the logic board, but the contactor does not close. Two possible reasons: the wires to the coil are interrupted or not well connected. the contact of the contactor is not properly working. ADEZP0AE - AC-2 INVERTER - User Manual Page - 57/64...
  • Page 58 LC (the module isn’t ready locked in an alarm state). Verify the other modules to determinate in which of them there is the problem. Page - 58/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 59: Inverter Diagnostic - Pump Configuration

    Two possible reasons: A) A real undervoltage / overvoltage situation happened. B) Fault in the hardware section of the logic board which manages the overvoltage protection. Replace the logic card. ADEZP0AE - AC-2 INVERTER - User Manual Page - 59/64...
  • Page 60 11) VACC NOT OK The test is made in standby. This alarm indicates that the accelerator voltage is 1V greater than the minimum value programmed by the PROGRAM VACC function. Page - 60/64 ADEZP0AE - AC-2 INVERTER - User Manual...
  • Page 61 The controller stops at 100 °C. If the alarm is signalled when the controller is cold: A) check the wiring of the thermal sensor; B) thermal sensor failure; C) logic failure. ADEZP0AE - AC-2 INVERTER - User Manual Page - 61/64...
  • Page 62 LC (the module isn’t ready locked in an alarm state). Verify the other modules to determinate in which of them there is the problem. Page - 62/64 ADEZP0AE - AC-2 INVERTER - User Manual...

  • Page 63: Recommended Spare Parts For Inverter

    Molex Minifit Connector 4 pins Female C12359 Molex Minifit Connector 6 pins Female C12407 Molex Minifit Connector 12 pins Female C12403 Molex Minifit Connector 14 pins Female C12777 Female Molex Minifit pin harness side ADEZP0AE - AC-2 INVERTER - User Manual Page - 63/64...

  • Page 64: Periodic Maintenance To Be Repeated At Times Indicated

    Zapi Agent immediately. The Agent will then take the decision regarding operational safety of the machine. Remember that Battery Powered Machines feel no pain. NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER. Page - 64/64 ADEZP0AE - AC-2 INVERTER - User Manual...

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