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Zapi COMBI AC1 Скачать руководство пользователя страница 7

2 SPECIFICATION

2.1 Technical specifications

Inverter for traction AC asynchronous 3-phase motors plus chopper for DC series
pump motors.
Regenerative braking functions.
Digital control based upon microcontroller
Voltage: ................................................................................................. 24, 36, 48V
Inverter maximum current (24V, 36V): ........................................350A (RMS) for 2'
Inverter maximum current (36V, 48V): ........................................300A (RMS) for 2'
Inverter operating frequency: .........................................................................  8kHz
Dc chopper Maximum current (24V,36V):.............................................  350A for 2'
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

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Содержание COMBI AC1

Страница 1: ...ECTRONIC 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 AC...

Страница 2: ...any 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 c...

Страница 3: ...ons and possible interferences 13 4 2 4 Wirings I O connections 15 4 2 5 Connection of the encoder 16 4 2 6 Main contactor and key connection 17 4 2 7 Insulation of truck frame 18 4 3 Protection and s...

Страница 4: ...MENTS functions list 54 9 5 5 Config menu TESTER functions list 55 10 OTHER FUNCTIONS 57 10 1 Description of console SAVE function 57 10 2 Description of console RESTORE function 58 10 3 Description o...

Страница 5: ...COMPANY FUNCTION INIZIALS SIGN GRAPHIC AND LAYOUT FF PROJECT MANAGER FG TECHNICAL ELECTRONIC MANAGER VISA PP SALES MANAGER VISA PN Publication N AEQZP0BA Edition August 2005 AEQZP0BA COMBI AC1 User Ma...

Страница 6: ...ontroller for Ac 700W to 3 5Kw AC motors Pump controller for series wounded DC motors up to 7 5 Kw Drivers for ON OFF electrovalves and for one proportional valve electrodistributor Can bus interface...

Страница 7: ...8V Inverter maximum current 24V 36V 350A RMS for 2 Inverter maximum current 36V 48V 300A RMS for 2 Inverter operating frequency 8kHz Dc chopper Maximum current 24V 36V 350A for 2 Dc chopper Maximum cu...

Страница 8: ...listed here following AMP SAAB version A7 A5 A11 A18 A19 A20 A33 A34 A35 A6 AMP SEAL version A1 A20 A6 A32 A31 A19 A7 A35 A17 A29 It is recommended to connect SAFETY RELATED devices to these double ch...

Страница 9: ...onnector On request it is also possible the handling in the Right side of next figure potentiometer in the middle at rest still in combination with a couple of Travel demand switches The Procedure for...

Страница 10: ...e The speed transducer is an incremental encoder with two phases shifted at 90 The encoder can be of different types power supply 12V electric output open collector NPN or PNP push pull COMBI AC1 coul...

Страница 11: ...e auxiliary circuits use cables 0 5mm section at least For power connections to the motor and to the battery use cables having section of 16 25 mm For the optimum inverter performance the and be as sh...

Страница 12: ...mm and rugosity 1 6 m Apply a light layer of thermo conductive grease between the two surfaces to permit better heat dissipation The heat generated by the power block must be dissipated For this to be...

Страница 13: ...al time control applications CAN operates at data rate of up to 1 Megabits per second It was invented by the German company Bosch to be used in the car industry to permit communication among the vario...

Страница 14: ...ends on the type of nodes modules connected in the The best s network t in terms of power then the preferable If the modules are very differen connection is the daisy chain Module 1 Module 2 Module 3...

Страница 15: ...y of today systems needs more and more data signal and information must flow from a node to another CAN is the solution to different problems that arise from this complexity simplified design readily...

Страница 16: ...5V 12V positive of encoder power supply A10 GND negative of encoder power supply A8 A phase A of encoder A22 B phase B of encoder AMPSEAL VERSION A25 5V 12V positive of encoder power supply A5 GND ne...

Страница 17: ...actor can be carried out following the drawing in the figure AMPSAAB VERSION AMPSEAL VERSION The connection of the battery line switches must be carried out following ZAPI instructions If a mechanical...

Страница 18: ...L VERSION 4 2 7 Insulation of truck frame U 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 b...

Страница 19: ...sted to carefully study controller installation and position With few simple shrewdness the degree of controller protection can be strongly increased Protection against uncontrolled movements The main...

Страница 20: ...functions 4 4 EMC U EMC and ESD performances of an electronic system are strongly influenced by the installation Special attention must be given to the lengths and the paths of the electric connection...

Страница 21: ...the controller with regard to electromagnetic f made by the electronic device There are well defined tests which the machine has to be exposed to These tests are carried out at determined levels of el...

Страница 22: ...th ground absorbing excess charge So it is strongly suggested to connect to truck frame all the parts of the truck which can be touched by the operator who is most of the time the source of ESD 4 5 Va...

Страница 23: ...ions Modification of parameters through the programming console Internal hour meter with values that can be displayed on the console Memory of the last five alarms with relative hour meter and tempera...

Страница 24: ...6 DESCRIPTION OF THE CONNECTORS 6 1 Connectors of the logic AmpSaab version 1 14 15 28 29 42 Page 24 86 AEQZP0BA COMBI AC1 User Manual...

Страница 25: ...o the Hard Soft microswitch active high A7 TILLER Tiller microswitch input active high VB A8 ENC A Traction motor encoder phase A A9 PENC Encoder Positive Supply 5 or 12Vdc A10 NENC Negative of the En...

Страница 26: ...s active high VB A34 IN7 Input of the switch DIGITAL INPUT 7 A35 IN8 Input of the switch DIGITAL INPUT 8 A36 LIFT SW Lift request switch input active high VB A37 LIFTING CUTOUT Lift stop input Active...

Страница 27: ...Negative serial reception pin A22 THMOT Traction motor thermal sensor input The internal pull up is a fixed 2mA Max 5V source current A23 NEV6 Output of the electrovalve 6 driver driving to Batt A24 N...

Страница 28: ...P B B Negative of the battery B Positive of the battery BF Positive of the battery before the fuse P Output of the Pump Motor U V W Connection bars of the three motor phases follow this sequence and...

Страница 29: ...7 DRAWINGS 7 1 Mechanical drawing AEQZP0BA COMBI AC1 User Manual Page 29 86...

Страница 30: ...7 2 Connection drawing 7 2 1 AmpSaab version Page 30 86 AEQZP0BA COMBI AC1 User Manual...

Страница 31: ...7 2 2 AmpSeal version AEQZP0BA COMBI AC1 User Manual Page 31 86...

Страница 32: ...ding on a jumper inside the controller Step5 Connect the plus battery voltage through a key switch at the KEY input CNA 13 CNA 10 in AmpSeal This is the input for the controller supply Step6 Connect t...

Страница 33: ...the machine Test the parameters in both directions Step7 Set the FREQUENCY CREEP level starting from 0 6 Hz The machine should just move when the accelerator microswitch is closed Increase the Level...

Страница 34: ...Step15 Make the choice for the truck behaviour on a slope If the Stop on ramp option is ON set the desired value of auxiliary time parameter Page 34 86 AEQZP0BA COMBI AC1 User Manual...

Страница 35: ...Description of console hand set connection 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 Za...

Страница 36: ...9 3 Description of the console menu 9 3 1 Master AmpSaab version Page 36 86 AEQZP0BA COMBI AC1 User Manual...

Страница 37: ...9 3 2 Master AmpSeal version AEQZP0BA COMBI AC1 User Manual Page 37 86...

Страница 38: ...9 3 3 Slave AmpSaab version Page 38 86 AEQZP0BA COMBI AC1 User Manual...

Страница 39: ...9 3 4 Slave AmpSeal version AEQZP0BA COMBI AC1 User Manual Page 39 86...

Страница 40: ...Display will show SET OPTIONS CONFIG MENU SET OPTIONS Press ENTER to go in the SET OPTIONS MENU The Display will show the first OPTION HOURCOUNTER RUNNING Press SET UP or SET DOWN button in order to m...

Страница 41: ...rm is raised when the battery level is calculated being less than or equal to 10 of the full charge The BATTERY LOW alarm inhibits the Lifting function 4 STOP ON RAMP Only when the encoder is present...

Страница 42: ...et OFF the Quick Inversion switch is Normally Open function active when switch closes 9 4 2 Config menu ADJUSTMENTS functions list To enter the CONFIG MENU it is necessary to push in the same time the...

Страница 43: ...is parameter together 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 correspondi...

Страница 44: ...2B ZAPI 0 00 24V 350A 00000 2 Press ENTER to go into the General Menu 3 The Display will show PARAMETER CHANGE MAIN MENU PARAMETER CHANGE 4 Press ENTER to go into the Parameter Change menu 5 The Displ...

Страница 45: ...ely released The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz 6 SPEED LIMIT BRK Seconds It controls the deceleration ramp when a speed reduction has been activated...

Страница 46: ...the speed percentage of the maximum speed in the inching mode 17 INCHING TIME When the inching mode is active for a period of time higher then this value the truck automatically stops and the operator...

Страница 47: ...X From 0 to 100 resolution of 1 INCHING SPEED Max Sp From 0 to 100 resolution of 1 INCHING TIME Sec From 0 to 10 sec resolution of 0 1 STOP SMOOTH Hz From 3 to 20 Hz resolution of 1Hz STOP BRAKE SMOOT...

Страница 48: ...plied to the motor expressed in per cent of the actual battery voltage Note when DC_LINK COMPENSATION is set ON the VOLTAGE BOOSTER reading will not match perfectly the booster setting because this la...

Страница 49: ...iller ON VB When it is closed to a battery key voltage the H S request is Active OFF GND When it is not connected to a battery key voltage or it is connected to GND the H S request is not active 14 DE...

Страница 50: ...When it is not closed to a battery key voltage or connected to GND the voltage the digital input 7 request is not active 21 IN 8 SWITCH Only for AmpSaab version ON OFF This is the level of the digital...

Страница 51: ...controlled Digital the related output manages an on off valve 3 EV1 TYPE Analog digital defines the type of the EV1 electrovalve voltage controlled Analog the related output manages a proportional val...

Страница 52: ...Set the deceleration ramp for the pump motor 4 SPEED LIMIT Percentage It limits the maximum speed of the lifting function Percentage of the maximum voltage applied to the pump motor 5 CREEP SPEED Perc...

Страница 53: ...lectrovalve when related output is set as Analog refer to Set Option menu 15 EV1 CLOSE DELAY In seconds It defines the closing ramp of the evp1 electrovalve when related output is set as Analog refer...

Страница 54: ...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 3 AUX OUTP...

Страница 55: ...MPERATURE C Measure of the pump motor temperature 7 LIFTING CONTROL Volt Measure of the lift lower potentiometer input signal CPOTLIFT CNA 25 in AmpSaab connector CNA 30 in AmpSeal connector 8 HANDLE...

Страница 56: ...S switch CNA 6 in AmpSaab CNA 29 in AmpSeal 18 DIGITAL INPUT 13 On off it determines if the input 13 is active or not Horn switch CNA 21 in AmpSaab 19 SET POINT EVP This parameter shows the setpoint...

Страница 57: ...pening Zapi Display CA1S2B ZAPI V0 0 24V 350A 00000 Press ENTER to go into the General menu The Display will show MAIN MENU PARAMETER CHANGE Press ROLL UP or ROLL DOWN button until SAVE PARAM appears...

Страница 58: ...oller memory will be written over and replaced with data being restored Flow Chart showing how to use the RESTORE function of the Digital Console Opening Zapi Display CA1S2B ZAPI V0 0 24V 350A 00000 P...

Страница 59: ...lly relating to the minimum level 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 indicate the point where...

Страница 60: ...SETTING 4 8 4 8 Press ENTER to clear these values Display will show 0 0 Select Forward Direction close any interlock switches that may be in the system MIN VACC MAX 0 0 0 0 Slowly depress the acceler...

Страница 61: ...an this percentage of the MAX VACC setting This adjustment define the width of a dead zone close to the neutral position THROTTLE X POINT THROTTLE Y POINT the speed of the truck grows up with a fixed...

Страница 62: ...t Max Adj and the Bat Min Adj It is possible to adapt the Battery Charge Detection to your specific battery by changing the above two settings e g if the Battery Discharged Detection occurs when the b...

Страница 63: ...t is compared with a threshold value function of the actual charge percentage in a table and with comparison is found a new charge percentage 4 Thresholds value can be changed with parameters Bat Max...

Страница 64: ...to the first time the alarm occurred In this way comparing this hourmeter with the controller hourmeter it is possible to determine When this alarm occurred the first time How many hours are elapsed...

Страница 65: ...Lc opened Eb applied start up Valve or pump or traction request Logic Failure 1 Waiting for trac Overvoltage Undervoltage condition has been detected Valve pump traction stopped Lc opened Eb applied...

Страница 66: ...ontroller internal charging resistance is damaged C The charging circuit has a failure inside the controller D There is a problem in the controller power section 2 VMN LOW Cause 1 start up test Before...

Страница 67: ...ED Cause Before switching the LC on the software checks the power bridge it turns on alternatingly the Low side and High side Power Mosfets and expects the phases voltage to decrease down to BATT incr...

Страница 68: ...tactor is stuck The controller drives the bridge for some tens milliseconds trying to discharge the capacitors bank If they don t discharge the fault condition is entered Troubleshooting It is suggest...

Страница 69: ...undervoltage or a overvoltage condition A If the alarm happens during traction acceleration or driving hydraulic functions it is very likely it is an undervoltage condition check battery charge condi...

Страница 70: ...k both the electric and the mechanical encoder functionality the wires crimping B Check the encoder mechanical installation if the encoder slips inside its compartment raising this alarm condition C A...

Страница 71: ...t of the controller which must be replaced 25 WRONG SETPOINT Cause This is a safety related test The Master C has detected a Slave C wrong hydraulic function setpoint Troubleshooting This is a interna...

Страница 72: ...tected in eeprom or in eeprom management Controller works using Deafult parameters continuous Motor temperature Motor temperature sensor is opened if digital or has overtaken the threshold of 150 C if...

Страница 73: ...ting sequence Troubleshooting The possible reasons for this alarm are use the readings in the TESTER to facilitate the troubleshooting A A travel demand active at key on B Presence man sensor active a...

Страница 74: ...al Switch the key off and on to check the result If the alarm occurs permanently it is necessary to replace the controller If the alarm disappears the previously stored parameters will have been repla...

Страница 75: ...de Troubleshooting Check the voltage on NPOT and the potentiometer connections 14 TILLER OPEN Cause Warning when the tiller is released after a fixed period of time of standby 30 seconds the main cont...

Страница 76: ...or traction request Safety Feed TG Waiting for Node Slave uC has detected a problem on the feedback of Lc driver valve pump traction stopped Lc opened Eb applied continuous Key re cycle Safety Feed E...

Страница 77: ...ions If motor windings cables have leakages towards truck frame That the LC power contact closer properly with a good contact If no problem are found on the motors the problem is inside the controller...

Страница 78: ...s due to overvoltage condition check line contactor contact battery power cable connection 6 WRONG ZERO Cause The outputs of the amplifiers used to measure the motor currents and voltage are checked t...

Страница 79: ...bus malfunctioning which blinds master slave communication Otherwise it is an internal fault of the controller which must be replaced 13 NO CAN MESSAGE 2 Cause No Can messages from the master microcon...

Страница 80: ...current feedback is always 0A even when pump motor is running Pump motor stopped pump function pump request motor temperature Pump Warning Pump motor temperature high Pump chopper maximum current red...

Страница 81: ...ives the outputs the problem is located in the harness and in the coils 4 VALVE DRIVER SHORTED Cause One or more on off valve drivers are shorted Troubleshooting Check if there is a short or a low imp...

Страница 82: ...ondition as a consequence the pump controller itself cannot enter an operative status but has to WAIT for the Master controller coming out from the fault condition 11 INCORRECT START Cause This is a w...

Страница 83: ...PROM operation refer to Console manual Switch the key off and on to check the result If the alarm occurs permanently it is necessary to replace the controller If the alarm disappears the previously st...

Страница 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...

Страница 85: ...SPARE PARTS Part number Description C16506 FUSE PROT 425A INTERAS60 for 24v and 48v version C12505 AMPSAAB CONNECTOR 42 pins Female C12532 AMPSEAL CONNECTOR 35 pins Female AEQZP0BA COMBI AC1 User Man...

Страница 86: ...e mechanical operation of the pedal or tiller Are the return springs ok Do the potentiometers wind up to their full or programmed level Check every 3 months Check the mechanical operation of the Conta...

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