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AF6ZP0AL - COMBIAC0 & ACE0 - User Manual

Page - 5/79

1 INTRODUCTION

The COMBI AC0 / ACE0 inverter has been developed to perform all the electric
functions that are usually presents in walkie and rider pallet trucks, stackers, low
level order pickers.
The controller can perform the following functions:

-

Controller for Ac 700W to 2,5 Kw AC motors;

Pump controller for series wounded DC motors up to 5 KW (only for Combi
AC0).

Drivers for ON/OFF electrovalves and for two proportional valves (electro-
distributor)

Can bus interface

Interface for canbus tiller

Zapi patented sensorless and sense coil control

128 Kbytes Flash memory embedded.

Software downloadable via Serial link or JTAG (internal connectors) or
Canbus (external connector)

ESD protection on CAN BUS inputs CANL and CANH

Содержание COMBI ACE0

Страница 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 COMBIAC0 A...

Страница 2: ...changes or improvements to its products at any time and without notice The present publication reflects the characteristics of the product described at the moment of distribution The publication ther...

Страница 3: ...Contactors 11 4 1 3 Fuses 12 4 2 Installation of the hardware 12 4 2 1 Positioning and cooling of the controller 12 4 2 2 Wirings power cables 13 4 2 3 Wirings CAN connections and possible interferen...

Страница 4: ...ns list 47 11 OTHER FUNCTIONS 51 11 1 Description of console SAVE function 51 11 2 Description of console RESTORE function 52 11 3 Description of console PROGRAM VACC function 53 11 4 Description of t...

Страница 5: ...unctions Controller for Ac 700W to 2 5 Kw AC motors Pump controller for series wounded DC motors up to 5 KW only for Combi AC0 Drivers for ON OFF electrovalves and for two proportional valves electro...

Страница 6: ...imum heatsink temperature start of the thermal cutback 85 C 4 Note 1 The DC chopper specifications are related to Combi AC0 2 2 Technical specifications Combi AC0 Power ACE0 Power Inverter for tractio...

Страница 7: ...AF6ZP0AL COMBIAC0 ACE0 User Manual Page 7 79 2 3 Block diagrams 2 3 1 Traction control 2 3 2 Pump control...

Страница 8: ...tches It is suggested that microswitches have a contact resistance lower than 0 1Ohm and a leakage current lower than 100 A When full load connected the voltage between the key switch contacts must be...

Страница 9: ...ogue input the PEDAL WIRE KO warning is lost whose typical application is a proportional command to enable a lifting lowering function It is possible to use this input for an alternative function like...

Страница 10: ...ACE0 could also be used without encoder sensorless control This solution has to be discussed with Zapi technicians 4 Note 1 The encoder resolution and the motor poles pair the controller can handle i...

Страница 11: ...es 0 5mm section at least For power connections to the motor and to the battery use cables having a minimum section of 15 mm For the optimum inverter performance the cables to the battery should be ru...

Страница 12: ...uggested characteristics are planarity 0 05 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 p...

Страница 13: ...twork It is a communication protocol for real 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 indus...

Страница 14: ...modules are very different in terms of power then the preferable connection is the daisy chain U Correct Layout Note Module 1 power Module 2 power Module 3 power The chain starts from the BATT post of...

Страница 15: ...N is the solution to different problems that arise from this complexity simplified design readily available multi sourced components and tools lower costs less and smaller cables improved reliability...

Страница 16: ...er power supply A5 GND negative of encoder power supply A14 A phase A of encoder A13 B phase B of encoder 2 Connection of encoder with open collector output 5V power supply Connection of encoder with...

Страница 17: ...wer battery line see picture below if not the inverter may be damaged if the switch is opened during a regenerative braking An intrinsic protection is present inside the logic when the voltage on the...

Страница 18: ...rotection meeting IP65 Nevertheless it is suggested to carefully study controller installation and position With few simple shrewdness the degree of controller protection can be strongly increased Pro...

Страница 19: ...g norms EN12895 for industrial truck EN50081 2 for other applications EMC stands for Electromagnetic Compatibility and it represents the studies and the tests on the electromagnetical energy generated...

Страница 20: ...nic devices There are different solutions for EMC issues depending on level of emissions immunity required the type of controller materials and position of the wires and electronic components 4 EMISSI...

Страница 21: ...low frequency choppers with COMBI AC0 ACE0 modules The filter capacitors contained in the COMBI AC0 ACE0 module would change the SCR chopper operation and subject to excessive workload If it is necess...

Страница 22: ...n 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 temperature displayed o...

Страница 23: ...switch is opened The default function is the controller CUTBACK input opening the switch truck speed is reduced A7 DI6 Input of the switch DI6 The input is activated when it is connected to Batt The...

Страница 24: ...d horn electrovalve driver driving to Batt A27 CANL Low level CAN BUS voltage I O A28 CANH High level CAN BUS voltage I O A29 DI9 Input of the switch DI9 The input is activated when the external switc...

Страница 25: ...api Flasher or for the communication with Zapi Handset or with lap top for controller setting an diagnosis 6 1 3 CNE internal connector The connector used is a 16 Vie STRIP E1 TMS JTAG interface test...

Страница 26: ...ual 7 DESCRIPTION OF POWER CONNECTIONS View of the power bars B Negative of the battery B Positive of the battery P Output of the Pump Motor U V W Connection bars of the three motor phases follow this...

Страница 27: ...AF6ZP0AL COMBIAC0 ACE0 User Manual Page 27 79 8 DRAWINGS 8 1 Mechanical drawing...

Страница 28: ...Page 28 79 AF6ZP0AL COMBIAC0 ACE0 User Manual 8 2 Connection drawing ACE0...

Страница 29: ...AF6ZP0AL COMBIAC0 ACE0 User Manual Page 29 79 8 3 Connection drawing CombiAC0...

Страница 30: ...y switch at the KEY input CNA 10 This is the input for the controller supply Step6 Connect the Main Contactor Coil to CNA 10 and CNA 12 The contactor must connect the battery positive to the BATT powe...

Страница 31: ...n 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 accordingly Step8 Set the Speed Re...

Страница 32: ...has to be connected through a remote module like a Zapi tiller card of a Zapi display This module has to be connected to the same Canbus line of the inverter Otherwise it is possible to connect a pc t...

Страница 33: ...AF6ZP0AL COMBIAC0 ACE0 User Manual Page 33 79 10 3Description of the console menu 10 3 1 ACE0 COMBIAC0 Menu...

Страница 34: ...isplay will show SET MODEL CONFIG MENU SET MODEL Press ROLL UP or ROLL DOWN button until SET OPTIONS menu appear The Display will show SET OPTIONS CONFIG MENU SET OPTIONS Press ENTER to go in the SET...

Страница 35: ...but is ignored it means no action is taken when the battery is discharged Level 1 BATTERY LOW alarm is raised when the battery level is calculated being less than or equal to 10 of the full charge Th...

Страница 36: ...load connected to CNA 9 or CNA 8 is activated When set ABSENT the diagnosis is not implemented 11 EV2 PRESENT ABSENT If set PRESENT the diagnosis EV2 DRIVER SHORTED relative to the load connected to...

Страница 37: ...activated 17 M C FUNCTION PRESENT ABSENT When is set PRESENT the Main Contactor is closed after the controller key on if the initial diagnosis pass If is set ABSENT the diagnosis are masked and M C i...

Страница 38: ...MENU appears 5 ADJUSTMENTS appears on the display CONFIG MENU ADJUSTMENTS 6 Press ENTER to go into the ADJUSTMENTS MENU 7 The display will show SET BATTERY TYPE BATTERY TYPE 24V 8 Press ROLL UP or ROL...

Страница 39: ...e upper level of the battery charge table Level 0 to 9 8 LOAD HM FROM MDI When set On the HourMeter of the Controller is transferred and recorded on the HourMeter of the MDI CAN connected to CAN BUS n...

Страница 40: ...s parameter stores the PWM value applied to MC coil and AUX COIL after the first second of the output activation It is expressed in percentage of battery voltage 17 PWM ON MAIN CONT OFF the inverter a...

Страница 41: ...RELEASE BRAKING LEVEL 5 8 When the desired Parameter appears it s possible to change the Level by pressing either SET UP or SET DOWN buttons 9 The Display will show the new level RELEASE BRAKING LEVE...

Страница 42: ...en activated The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz 8 MAX SPEED FWD Percentage It determines the maximum speed in forward direction 9 MAX SPEED BWD Perce...

Страница 43: ...to 9 Set the maximum current for the pump motor 24 PUMP ACCELERATION DELAY In seconds Set the acceleration ramp for the pump motor 25 PUMP DECELERATION DELAY In seconds Set the deceleration ramp for t...

Страница 44: ...VP2 is programmed like a On Off valve this parameter determines the fixed voltage applied on the electrovalve coil 33 EVP OPEN DELAY In seconds It defines the opening ramp of the EVP1 electrovalve whe...

Страница 45: ...m 3 to 20 Hz resolution of 1Hz BRK SMOOTH Num From 1 to 5 resolution 0 1 STOP BRAKE SMOOTH Hz From 3 to 20 Hz resolution of 1Hz AUXILIARY TIME Sec From 0 to 10 sec resolution of 0 1 HYDRO TIME Sec Fro...

Страница 46: ...TURE Set the temperature offset to have the correct value reading This is a fine calibration of the controller temperature sensor 5 ADJUSTMENT 03 Factory adjusted value This is the gain of the Current...

Страница 47: ...e really supplied 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 bec...

Страница 48: ...nput ON VB When it is closed to a battery key voltage the Tiller input is Active OFF GND When it is not connected to a battery key voltage or it is connected to GND the Tiller input is not active 17 D...

Страница 49: ...NG request is not active 24 DI8 BACKING FOR ON OFF This is the level of the digital input CNA 17 for the inching forward request ON VB When it is closed to a battery key voltage the forward inching de...

Страница 50: ...ITCH ON OFF This is the level of the digital input CNA 21 ON VB When it is closed to a battery key voltage the digital input 12 is active OFF GND When it is not closed to a battery key voltage or it i...

Страница 51: ...the Digital Console Opening Zapi Display CA0Z2A ZP1 00 24V 200A 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 S...

Страница 52: ...ll data in the controller 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 CA0Z2A ZP1 00...

Страница 53: ...nts associated with the potentiometer especially 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 con...

Страница 54: ...r output Both directions can be shown VACC 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 V...

Страница 55: ...om the accelerator potentiometer is lower than 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 t...

Страница 56: ...ltage Level 10 These two settings are the Bat 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 Ba...

Страница 57: ...ter the samples are took on key input 3 Vbatt 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 v...

Страница 58: ...the hourmeter indicated in this memory refers 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 occurr...

Страница 59: ...of EB coil is damaged not able to close Valve pump traction stopped Lc opened Eb applied stby traction Valve or pump or traction request Pos EB shorted MDI CAN 86 Output of built in Smart Driver whic...

Страница 60: ...re the motor voltage are cheked this alarm occurs when voltage signals 3V or 2V at the init valve pump traction stopped Lc opened Eb applied init valve or pump or traction request Evp1 coil open MDI C...

Страница 61: ...B The charging resistance is opened insert a power resistance across line contactor power terminals if the alarm disappears it means the controller internal charging resistance is damaged C The chargi...

Страница 62: ...nnections If motor phases windings cables have leakages towards truck frame If no problem are found on the motors the problem is inside the controller 4 POWER MOS SHORTED Cause Before switching the LC...

Страница 63: ...discharge the capacitors bank If they don t discharge the fault condition is entered Troubleshooting It is suggested to verify the power contacts of LC to replace the LC is necessary 10 AUX DRIVER SHO...

Страница 64: ...ely it is an undervoltage condition check battery charge condition power cable connection B If the alarm happens during release braking it is very likely it is due to overvoltage condition check line...

Страница 65: ...t raising this alarm condition C Also the electromagnetic noise on the sensor bearing can be a cause for the alarm In these cases try to replace the encoder D If the problem is still present after rep...

Страница 66: ...ts a mismatch between the valve set point and the diver voltage measured on the LOWER EVP1 output Troubleshooting Check if there is a short or a low impedance between the negative of the coil and BATT...

Страница 67: ...T OPTION menu is set ANALOG or DIGITAL but no load is connected between the output and PAUX positive Troubleshooting A It is suggested to check the harness in order to verify if EVP1 coil is connected...

Страница 68: ...Cause The software was not correctly written into the flash memory or the flash memory is damaged Troubleshooting This type of fault is not related to external components replace the controller 34 CUR...

Страница 69: ...s continuous Motor temperature MDI CAN 65 Traction motor temperature sensor is opened if digital or has overtaken the threshold of 150 C if analog The maximum current is reduced to half and speed is r...

Страница 70: ...of permitted stby range Pump motor stopped start up stby pump request Pump I 0 ever MDI CAN 52 Pump current feedback is always 0A even when pump motor is running Pump motor stopped pump function pump...

Страница 71: ...litate the troubleshooting A A travel demand active at key on B Presence man sensor active at key on Check the wirings Check the micro switches It could be also an error sequence made by the operator...

Страница 72: ...If the alarm disappears the previously stored parameters will have been replaced by the default parameters 8 MOTOR TEMPERATURE Cause This warning occurs when the temperature sensor is opened if digit...

Страница 73: ...es 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...

Страница 74: ...is a short or a low impedance between the negative of this coil and BATT This warning occurs also if the external load is not present and the parameter EV3 in the Set Options menu is set PRESENT in th...

Страница 75: ...the problem could be in the current sensor or in the related circuit 28 RAM WARNING Cause Checksum of the ram failed Troubleshooting This fault is not related to external components 29 EEP WARNING Ca...

Страница 76: ...ace the controller 36 TH PROTECTION Cause The controller detected a high temperature and the performance of the motor is limited Troubleshooting It is suggested to check the cause of the high temperat...

Страница 77: ...V inputs use the readings in the Tester to facilitate the troubleshooting Check the microswitches for failures A failure in the logic is possible too So if you have verified through the tester that th...

Страница 78: ...79 AF6ZP0AL COMBIAC0 ACE0 User Manual 13 RECOMMENDED SPARE PARTS Part number Description C12532 AMPSEAL CONNECTOR 35 pins Female C29508 SW 180 24V Single Pole Contactor C29522 SW 180 48V Single Pole C...

Страница 79: ...nt parts used should be original Beware of NON ORIGINAL PARTS The installation of this electronic controller should be made according to the diagrams included in this Manual Any variations or special...

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