Zapi AC-2 User Manual Download Page 63

Page: 63 / 64

9 RECOMMENDED SPARE PARTS FOR

INVERTER

Part number

Description

C16507

Protected 500 A strip Fuse.

C16505

Protected 355 A strip Fuse.

C16520

6.3 A 20 mm Control Circuit Fuse

C29523

SW 180 80 V
Single Pole Contactor

C29522

SW 180 48 V
Single Pole Contactor

C29508

SW 180 24 V
Single Pole Contactor

C12442

Molex Minifit Connector 2 pins Female

C12358

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

Summary of Contents for AC-2

Page 1: ...TRONIC 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 INVER...

Page 2: ...ny time and without notice The present publication reflects the characteristics of the product described at the moment of distribution The publication therefore does not reflect any changes in the cha...

Page 3: ...ns 20 4 8 Mechanical drawing 21 4 9 Connection drawing Traction configuration 22 4 10 Connection drawing Pump configuration 23 4 11 Connection drawing Combi configuration 24 5 PROGRAMMING ADJUSTMENTS...

Page 4: ...8 AC 2 INVERTER DIAGNOSTIC PUMP CONFIGURATION 59 8 1 Analysis of alarms displayed on console 59 9 RECOMMENDED SPARE PARTS FOR INVERTER 63 10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED 64...

Page 5: ...y 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 ADEZP0...

Page 6: ...250 A RMS for 3 Booster all version 10 of maximum current for some seconds Operating frequency 8 kHz External temperature range 30 C 40 C Maximum inverter temperature at full power 75 C 2 2 Block dia...

Page 7: ...ure is described in the programming console manual The two graphs show the output voltage from a non calibrated potentiometer with respect to the mechanical zero of the control lever MI and MA indicat...

Page 8: ...tection meeting IP54 5 Protection against uncontrolled movements The main contactor will not close if The Power unit is not functioning The Logic is not functioning perfectly The output voltage of the...

Page 9: ...med time High efficiency of motor and battery due to high frequency commutations Self diagnosis with indication of the fault shown by a flashing led Modification of parameters through the programming...

Page 10: ...nnect ASYNCHRONOUS from the battery Supply the ASYNCHRONOUS only with battery for traction do not use a power supply When the controller is installed make tests with the wheels raised from the ground...

Page 11: ...nside 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...

Page 12: ...n the SAFETY circuit the microcontroller itself will bring the machine in a safe status Suggested connection of SAFETY circuit STANDALONE CONFIGURATION it is suggested to connect safety input to the S...

Page 13: ...run side by side and be as short as possible 4 2 Contactors The main contactor must be installed Depending on the position of a jumper installed in the logic board the output which drives the main co...

Page 14: ...nsmission A5 GND Negative console power supply A6 12 Positive console power supply A7 FLASH It must be connected to A8 for the Flash memory programming if used A8 FLASH It must be connected to A7 for...

Page 15: ...nected to the brake pedal switch active high E8 CPOTB Brake potentiometer wiper E9 PPOTB Brake potentiometer positive 10 V output keep load 1 k E10 NPOTB Batt E11 BATT Batt E12 BACK FORW Inching funct...

Page 16: ...f main contactor coil F9 NBRAKE Output for driving a brake or an hydraulic steering contactor coil it drives the load to Batt maximum current 3 A F10 SR HB Speed reduction handbrake input Active low s...

Page 17: ...CAN BUS voltage I O D1 D6 Incremental ENCODER connector see chapter 4 6 E1 CPOT Accelerator potentiometer wiper E2 PPOT Potentiometer positive 10 V output keep load 1 k E3 NPOT Negative of accelerato...

Page 18: ...ntactor it drives the load to Batt Maximum current 3 A F10 2nd SPEED Input for second speed request it is active HIGH F11 GND Batt F12 NTHERM Batt 4 6 Encoder installation 1 AC 2 card is fit for diffe...

Page 19: ...ply VERY IMPORTANT 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...

Page 20: ...ions 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 AD...

Page 21: ...4 8 Mechanical drawing ADEZP0AE AC 2 INVERTER User Manual Page 21 64...

Page 22: ...4 9 Connection drawing Traction configuration Page 22 64 ADEZP0AE AC 2 INVERTER User Manual...

Page 23: ...4 10Connection drawing Pump configuration ADEZP0AE AC 2 INVERTER User Manual Page 23 64...

Page 24: ...4 11Connection drawing Combi configuration Page 24 64 ADEZP0AE AC 2 INVERTER User Manual...

Page 25: ...er s configuration are made using the 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 inv...

Page 26: ...5 3 Description of Standard Console Menu 5 3 1 Traction configuration Page 26 64 ADEZP0AE AC 2 INVERTER User Manual...

Page 27: ...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: ...magnetic brake coil see also the table below HYDRO CONT the inverter manages an hydraulic steering function when the direction input or brake pedal input are active or a movement of the truck is detec...

Page 29: ...IN It records the minimum value of braking pedal potentiometer when the braking pedal switch is closed the procedure is similar to the Program Vacc function see chapter 6 4 This procedure must be carr...

Page 30: ...9 ADJUSTMENT 03 This parameter isn t used 10 ADJUSTMENT 02 It adjusts the lower level of the battery discharge table 11 ADJUSTMENT 01 It adjusts the upper level of the battery discharge table 12 LOAD...

Page 31: ...hed HYDRO CONT OFF It drives the coil of a hydraulic steering contactor The hydraulic steering function request is also sent to the pump inverter by the can bus link The truck is not electrically hold...

Page 32: ...request NONE no motor thermal sensor switch is connected SUBMENU ADJUSTMENTS 1 SET BATTERY TYPE It selects the nominal battery voltage 2 ADJUST BATTERY Fine adjustment of the battery voltage measured...

Page 33: ...ed 8 ADJUSTMENT 02 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 po...

Page 34: ...will shows the first OPTION HOUR COUNTER RUNNING 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 Desired OPTION appears BATTERY CHECK OFF 10 Press SET UP or SET DOWN button in order...

Page 35: ...ears on the display CONFIG MENU ADJUSTMENTS 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will shows SET BATTERY TYPE BATTERY TYPE 48V 8 Press ROLL UP or ROLL DOWN button until the desir...

Page 36: ...display CONFIG MENU ADJUSTMENTS 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will show SET BATTERY TYPE SET BATTERY TYPE 80V 8 Press SET UP to choose nominal value of the battery 9 New...

Page 37: ...TTERY TYPE 80V 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 ADJUST BATTERY appears ADJUSTMENT BATTERY 82 1V 10 Press SET UP or SET DOWN button in order to increase or decrease re...

Page 38: ...K It determines the deceleration ramp when the speed reduction input becomes active and the motor slow down 7 MAX SPEED FORW It determines the maximum speed in forward direction 8 MAX SPEED BACK It de...

Page 39: ...l ramp calculated by the software the real ramp could change as a function of motor control parameter setting and obviously as a function of the load The braking feature is based upon deceleration ram...

Page 40: ...60 70 80 90 100 SPEED FINE ALL Hz MAXIMUM CURRENT IMAX 47 53 58 64 70 76 82 88 94 100 AUXILIARY TIME Sec 0 0 2 0 4 0 8 1 0 1 5 2 0 3 0 4 0 5 0 The acceleration time shown is the time from 0 Hz to 100...

Page 41: ...ween 0 and 9 Press either PARAM Top Right or SET Bottom Right buttons to change the Level value 9 The Display will show the New Level RELEASE BRAKING LEVEL 6 10 When you are satisfied with the results...

Page 42: ...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 n...

Page 43: ...rements follow the sequence detailed here following Remember to re cycle the Key Switch if you make any changes to the controller s configuration 1 Select the Options required See Chapter 5 4 2 2 Sele...

Page 44: ...level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 9 FORWARD SWITCH The level of the Forward direction digital entry FW ON VB acti...

Page 45: ...nction of the console The Console acts as a multimeter able to read voltage current and temperature The following definition listing shows the relative measurements 1 MOTOR VOLTAGE This is the voltage...

Page 46: ...SWITCH Status of the fourth speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 14 HYDRO SPEED REQ Status of the hydro speed request of the pump ON VB...

Page 47: ...NTER to go into the TESTER function 7 The first variable to be tested is shown on the Display MOTOR VOLTAGE 8 Press either ROLL UP or ROLL DOWN buttons until your desired variable for measurement appe...

Page 48: ...Display AC2 ZAPI V0 0 48V 350A 00000 2 Press ENTER to go into the General menu 3 The Display will show MAIN MENU PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until SAVE PARAM appears on the di...

Page 49: ...12 Press OUT to return to the Opening Zapi Display ADEZP0AE AC 2 INVERTER User Manual Page 49 64...

Page 50: ...use the RESTORE function of the Digital Console 1 Opening Zapi Display AC2 ZAPI V0 0 48V 350A 00000 2 Press ENTER to go into the General menu 3 The Display will show MAIN MENU PARAMETER CHANGE 4 Press...

Page 51: ...d in the inverter memory whilst the RESTORE routine is happening STORING ACCELER DELAY 13 When finished the Console displays MAIN MENU RESTORE PARAM 14 Press OUT to return to the Opening Zapi Display...

Page 52: ...Display will show MAIN MENU PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display 5 The Display will show MAIN MENU ALARMS 6 Press ENTER to go into the AL...

Page 53: ...on the display 5 The Display will show MAIN MENU PROGRAM VACC 6 Press ENTER to go into the PROGRAM VACC routine 7 The Display will show the minimum and maximum values of potentiometer wiper output Bot...

Page 54: ...15 When finished the Console shows MAIN MENU PROGRAM VACC 16 Press OUT again to return to the Opening Zapi Menu Page 54 64 ADEZP0AE AC 2 INVERTER User Manual...

Page 55: ...in the SAFETY circuit CAN BUS KO SAFETY SAFETY KO long blink discharge battery or wrong battery voltage LOW BATTERY WRONG SET BATT no blink problem in a remote module WAITING FOR NODE 7 1 Analysis of...

Page 56: ...place the logic 9 HANDBRAKE The truck does not start because the handbrake switch is opened Possible causes A defective wiring B failure of the microswitch C incorrect operation of the operator D if t...

Page 57: ...which inhibits machine operations Possible causes A current sensor failure B logic failure first replace the logic if the defect persists replace the power unit 17 DATA ACQUISITION This alarm is signa...

Page 58: ...a warning is signalled if it is out of range When this alarm is signalled check the connection of the sensors 24 CAN BUS KO The diagnosis of the CAN BUS line is present only if the inverter uses this...

Page 59: ...k discharge battery or wrong battery voltage LOW BATTERY WRONG SET BATT no blink problem in a remote module WAITING FOR NODE 8 1 Analysis of alarms displayed on console 1 WATCH DOG The test is made in...

Page 60: ...nsor bearing can be a cause for the alarm 8 CAPACITOR CHARGE Follows the charging capacitor system When the key is switched ON the inverter tries to charge the capacitors through a power resistance an...

Page 61: ...e FF SR makes an hardware control of the current in the MC coil If this is too high it opens the MC and the alarm is signalled Check if there are external shortcircuit and if the ohmic value of the MC...

Page 62: ...board which must be replaced 21 SAFETY This alarm is signalled when the SAFETY input is open The SAFETY circuit gets active and opens the drivers of LC and EB and stops the machine Verify the SAFETY i...

Page 63: ...actor C29522 SW 180 48 V Single Pole Contactor C29508 SW 180 24 V Single Pole Contactor C12442 Molex Minifit Connector 2 pins Female C12358 Molex Minifit Connector 4 pins Female C12359 Molex Minifit C...

Page 64: ...Check the mechanical operation of the Contactor s Moving contacts should be free to move without restriction Check every 3 months Checks should be carried out by qualified personnel and any replaceme...

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