Zapi COMBI AC1 Bedienungsanleitung

ELECTRONIC • OLEODYNAMIC • INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY Tel +39 0522 960050 (r.a.) – Fax +39 052

Also in AmpSeal version a third analog input is available in CNA#17 (a digital input is lost). These other two analog inputs are checked by both micro

4 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colours, they mean: 4 These are infor

4.1.3 Fuses - Use a 6.3-10A Fuse for protection of the auxiliary circuits. - For protection of the power unit, use a 400A fuse in the Battery Positi

4.2.2 Wirings: power cables - The power cables length must be as short as possible to minimize power losses. - They must be tightened on controlle

U Wrong Layout: The red lines are can wires. ample traction controller, pump The black boxes are different modules, for exnbus. controller and disp

Otherwise, if two controllers are similar in power (for example a traction and a pump motor controller) and a third module works with less current,

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

AMPSEAL VERSION U VERY IMPORTANT It is necessary to specify in the order the type of encoder used, in terms of power supply, electronic output and n

voltage or if the key is switched off before the battery power line is disconnected. AMPSAAB VERSION AMPSEAL VERSION 4.2.7 Insulation of truck f

4.3 Protection and safety features 4.3.1 Protection features The COMBI AC1 is protected against some controller injuries and malfunctions: - Battery

Copyright © 1975-2006 Zapi S.p.A. All rights reserved The contents of this publication is a ZAPI S.p.A. property; all related authorizations are cove

4.3.2 Safety Features U ZAPI controllers are designed according to the prEN954-1 specifications for safety related parts of control system and to UNI

switching of the mosfets which are working at high frequency and generaRF energy, but wires and cables have the key role to propagate the disturbs bec

3) ELECTROSTATIC IMMUNITY. Three ways can be followed to prevent damages from ESD: A) PREVENTION: when handling ESD-sensitive electronic parts, en

5 OPERATIONAL FEATURES - Speed control. - Optimum behaviour on a slope if the speed feedback is used: - The motor speed follows the accelerator,

6 DESCRIPTION OF THE CONNECTORS 6.1 Connectors of the logic AmpSaab version 114152829 42 Page - 24/86 AEQZP0BA – COMBI AC1 - User Manual

AmpSeal Version 11324122335 6.1.1 CNA connector: AmpSaab Version The connector used is a AMPSAAB plug 42 pins A1 NCLTXD Negative serial transmissi

A18 FW Forward switch input, active high (+VB). A19 BACK Reverse switch input, active high (+VB). A20 IN5 Input of the switch DIGITAL INPUT # 5.

A8 NEV5/HORN OUT Out of the electrovalves/Horn driver (driving to –Batt). A9 NEV1 Output of the electrovalve 1 driver (driving to –Batt) A10 +KEY

6.2 Description of power connections View of the power bars: U+BF -BVW-P+B -B Negative of the battery. +B Positive of the battery. +BF Positive o

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

Contents 1 INTRODUCTION ...6 2 SPECI

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

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

8 ONE SHOT INSTALLATION PROCEDURE This section of the manual describes the basic connection procedure. To move, the truck needs a minimum I/O outfit t

You must fill your I/O outfit with your optional functions. The optional functions are shown in the connecting drawing and described in detail inside

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 tim

9 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE 9.1 Adjustments via console Adjustment of Parameters and changes to the inverter’s configuration

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

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

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

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

9.2 Description of console (hand set) & connection ...35 9.3 Description of the console menu

9.4 Function configuration (MASTER) 9.4.1 Config menu “SET OPTIONS” functions list To enter the CONFIG MENU’ it is necessary to push in the same tim

connected to a key voltage when the operator is present. There are two levels: - HANDLE: CNA#7 [CNA#1 in AmpSeal] is managed as tiller input (no de

- NONE: The quick inversion function is not managed (no effect when CNA#33 switches over). - TIMED: The quick inversion function is timed. - BEL

TROTTLE 0 ZONE 7% 11) Press OUT ' ' ' ' % ' 12) Press ENTER to confirm ' % ' ' ' ' 13)

- NONE: No CHECK UP NEENED warning - OPTION#1: CHECK UP NEENED warning shown on the hand set and MDI after 300 hours - OPTION#2: Equal to OPTION#

13) The Display will show MAIN MENU PARAMETER CHANGE 1) ACCELER. DELAY Seconds. It determines the acceleration ramp. The parameter sets the time n

12) HS CUTBACK Typically from 10% to 100%. It determines the percentage of the max speed applied when the Hard & Soft function (H&S switch on

PROGRAMMED LEVEL PARAMETER UNIT 0 1 2 3 4 5 6 7 8 9 ACCELERATION DELAY Sec. From 0 to 10 sec., resolution of 0.1 RELEASE BRAKING Sec. From 0

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

analog sensor inside the motor. Normally this sensor is a PTC Philips KTY84-130. This temperature is used only to raise a warning in the hand set whe

APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN GRAPHIC AND LAYOUT FF PROJECT MANAGER FG TECHNICAL ELECTRONIC MANAGER VISA PP SALES MANAGER VIS

- ON +VB = When it is closed to a battery (key) voltage, the Backward Travel demand is Active. - OFF GND = When it is not connected to a battery (ke

ON/OFF. This is the level of the CNA#37 digital input (only in AmpSaab connector): - ON GND = When CNA#37 is not closed to a battery (key) voltage (o

3) THROTTLE Y POINT This parameter, together with the THROTTLE X POINT, changes the characteristic of the lift/lower accelerator input curve (see a

10) MIN EVP 0 to 100. This parameter determines the minimum voltage applied on the EVP when the position of the potentiometer is at the minimum. This

9.5.4 Config menu “SPECIAL ADJUSTMENTS ” functions list 1) ADJUSTMENT #1 (Factory adjusted). % value. This is the Gain of the Pump chopper Current S

9.5.5 Config menu “TESTER ” functions list 1) MOTOR CURRENT Ampere. It is the current in the motor controlled by the slave of combiac1. 2) MOTOR VO

14) DIGITAL INPUT 6 On/off : it determines if the input 6 is active or not (Belly switch, CNA#33 in AmpSaab, CNA#7 in AmpSeal). 15) DIGITAL INPUT 7 O

10 OTHER FUNCTIONS 10.1 Description of console “SAVE” function The SAVE function allows the operator to transmit the Parameter values and Configurati

Press OUT to return to the Opening Zapi Display ' ' ' ' % ' NOTE: in reality the SAVE and RESTORE function requires the

Press ENTER for YES, or OUT for No ' % ' ' ' ' ' ' '' % 'You can see the items that are being

1 INTRODUCTION The COMBI AC1 inverter has been developed to perform all the electric functions that are usually presents in walkie trucks, stackers, l

Flow Chart showing how to use the PROGRAM VACC function of the Digital Console. Opening Zapi Display CA1S2B ZAPI V0.0 24V 350A 00000 Press ENTER t

10.4 Description of the throttle regulation This regulation applies a not linear relationship between the position of the accelerator and the speed of

10.5 Description of the battery charge detection setting The Battery Charge detection uses two setting that specify the Full Charge Voltage Level (100

The Battery Charge detection follows this algorithm: 1) Battery voltages is read when the Battery current is zero, that is when the output power sta

11 COMBI AC1 ALARMS LIST The ALARMS logbook in the MAIN MENU’ records the alarms of the controller. It has a FIFO (First Input First Output) structure

11.2 Master microcontroller alarms overview Master error codeRelated slave error codeDescription EffectMachine status when the test is doneRestartp

11.3 Analysis and troubleshooting of Master microcontroller alarms To Enter the MAIN MENU’ push the Enter button at the Home Page of the hand set dis

- If no problem are found on the motors, the problem is inside the controller. 3) “VMN HIGH” Cause 1: Before switching the LC on, the software check

The driver of the main contactor coil is shorted. Troubleshooting: A) Check if there is a short or a low impedance pull-down between NMCC (CAN#17 in

B) If, even disconnecting the wire from the connector pin, the output stays at high value, the problem is inside the controller and the Smart Driver

2 SPECIFICATION 2.1 Technical specifications Inverter for traction AC asynchronous 3-phase motors plus chopper for DC series pump motors. Regenerative

window around the nominal value. Troubleshooting: A) Check that the controller SET BATTERY parameter value matches the battery nominal voltage. B) C

Troubleshooting: The problem is inside the logic of the inverter, replace the controller. 24) “NO CAN MESSAGE N5” Cause: No Can messages from the sla

11.4 Master warnings overview Master error codeRelated Slave error codeDescription EffectMachine status when the test is doneRestartprocedurePump Wa

11.5 Analysis and troubleshooting of Master warnings 1) “PUMP WARNING” Cause: The slave has a warning. Troubleshooting: Connect to the slave with the

Troubleshooting: Improve the air cooling of the controller. If the alarm is signalled when the controller is cold, the possible reasons are a thermal

Troubleshooting: The alarm ends when the acquisition is done. 13) “PEDAL WIRE KO” Cause: The SW continuously checks for the connection of the two sup

11.6 Slave alarms overview Slave error codeRelated Master error codeDescription EffectMachine status when the test is doneRestartprocedureEvp Driver

11.7 Analysis and troubleshooting of Slave alarms 1) “EVP DRIVER SHORTED” Cause: The EVP driver is shorted. Troubleshooting: Check if there is a sh

undervoltage condition. Overvoltage threshold is 45V, undervoltage threshold is 9V in the 24V controller. In 48V controller overvoltage threshold is 6

11) “OUTPUT MISMATCH” Cause: This is a safety related test. Slave µC has detected that the Master µC is driving traction motor in a wrong way (not cor

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].

11.8 Slave warnings overview Slave error codeRelated Master error codeDescription EffectMachine status when the test is doneRestartprocedureCurrent S

11.9 Analysis and troubleshooting of Slave warnings 1) “CURRENT SENSOR LOW” Cause: The pump chopper current sensor feedback is too low (below 0.5V).

8) “PUMP I=0 EVER” Cause: This test is carried out when the pump motor is running, and it verifies that the current feedback sensor is not constantly

14) “EEP WARNING” Cause: Eeprom checksum failed Troubleshooting: Try to execute a CLEAR EEPROM operation (refer to Console manual). Switch the key of

19) “REDUCTION BY MASTER” Cause: The master has requested a reduction of performance of the slave. Troubleshooting: Check in the master the cause of

12 RECOMMENDED SPARE PARTS Part number Description C16506 FUSE PROT. 425A INTERAS60 (for 24v and 48v version) C12505 AMPSAAB CONNECTOR 42 pins

13 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors’ moving and fixed contacts. Electrical Contac

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 consi