Zapi COMBI AC1 User Manual

Summary of COMBI AC1

  • 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 en user manual combi ac1.

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    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 covered by copyright. Any partial or total reproduction is prohibited. Under no circumstances will zapi s.P.A. Be held responsible to third parties for dam...

  • Page 3: Contents

    Contents 1 introduction ...................................................................................................................6 2 specification ...................................................................................................................7 2.1 technical specificatio...

  • Page 4

    9.2 description of console (hand set) & connection ....................................................... 35 9.3 description of the console menu .............................................................................. 36 9.3.1 master: ampsaab version .............................................

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    Approval signs 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 manual page - 5/86.

  • Page 6: 1 Introduction

    1 introduction the combi ac1 inverter has been developed to perform all the electric functions that are usually presents in walkie trucks, stackers, low order pickers etc. The controller can perform the following functions: - controller for ac 700w to 3.5kw ac motors; - pump controller for series wo...

  • Page 7: 2 Specification

    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: .................................................................................

  • Page 8: 3.1 Digital Inputs

    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]. Related command devices (microswitches) must be connected to +b (typically to key voltage). Pull-down resistance to –b is built-in. Functional devices...

  • Page 9: 3.2 Analog Unit

    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 consist of a potentiometer or an hall effect device. It should be in a 3-wire configuration. The potentiometer is supplied through cna#26 [ampsaab connector...

  • Page 10: 3.5 Speed Feedback

    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 microcontrollers too. 3.4 analog motor thermal sensor input input cna#12 in the ampsaab version [cna#22 in ampseal connector] is an analog input to receive...

  • Page 11: 4 Installation Hints

    4 installation hints in the description of these installation suggestions you will find some boxes of different colours, they mean: 4 these are informations useful for anyone is working on the installation, or a deeper examination of the content u these are warning boxes , they describe: - operation...

  • Page 12

    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 positive connection. For special applications or requirements these values can be reduced. - for safety reasons, we recommend the use of protected fuses in or...

  • Page 13

    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 controller power posts with a torque of 13-15 nm - the combi ac-1 module should only be connected to a traction battery. Do not use converters outputs or power sup...

  • Page 14

    U wrong layout: the red lines are can wires. Ample traction controller, pump the black boxes are different modules, for ex nbus. Controller and display connected by ca he black lines are the power cables. T this is apparently a good layout, but can bring to errors in the can line. Olution depends on...

  • Page 15

    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, the best way to deal this configuration is to create a common ground point (star configuration) u correct layout: note: module 1 power ≈ module 2 power ...

  • Page 16

    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 install an incremental encoder with 2 phases shifted of 90°. The encoder power supply can be +5 or +12v. It can have different electronic output. Ampsaa...

  • Page 17

    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° of pulses for revolution, because the logic unit must be set in the correct way by zapi. The n° of pulses revolution the controller can handle is give...

  • Page 18

    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 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 truc...

  • Page 19

    4.3 protection and safety features 4.3.1 protection features the combi ac1 is protected against some controller injuries and malfunctions: - battery polarity inversion it is necessary to fit a line contactor to protect the controller against reverse battery polarity and for safety reasons. - connect...

  • Page 20: 4.4 Emc

    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 en1175-1 norm. The safety of the machine is strongly related to installation; length, layout and screening of electrical connections have to be carefu...

  • Page 21

    Switching of the mosfets which are working at high frequency and genera rf energy, but wires and cables have the key role to propagate the disturbs because they works as antennas , so a good layout of the te cables and their shielding can solve the majority of the emission problems. 2) es: protectio...

  • Page 22: 4.5 Various Suggestions

    3) electrostatic immunity. Three ways can be followed to prevent damages from esd: a) prevention: when handling esd-sensitive electronic parts, ensure the operator is grounded; test grounding devices on a daily basis for correct functioning; this precaution is particularly important during controlle...

  • Page 23: 5 Operational Features

    5 operational features - speed control. - optimum behaviour on a slope if the speed feedback is used: - the motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set-point - the system can perform an electrical stop on a ramp (the machine is electrical...

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    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.

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    Ampseal version 1 13 24 12 23 35 6.1.1 cna connector: ampsaab version the connector used is a ampsaab plug 42 pins a1 ncltxd negative serial transmission pin. A2 pcltxd positive serial transmission pin. A3 nevp negative of the proportional electrovalve. A4 paux positive supply for electrovalves. Thi...

  • Page 26

    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. A21 horn horn switch input, active high (+vb). A22 enc b traction motor encoder phase b. A23 npot negative of the accelerator potentiometer, tested for wir...

  • Page 27

    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 input of the key switch signal. A11 nev2 output of the electrovalve 2 driver (driving to –batt) a12 nmc output of the line contactor coil driver (driving ...

  • Page 28

    6.2 description of power connections view of the power bars: u +bf -b v w -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 the indicati...

  • Page 29: 7 Drawings

    7 drawings 7.1 mechanical drawing aeqzp0ba – combi ac1 - user manual page - 29/86.

  • Page 30: 7.2  Connection Drawing

    7.2 connection drawing 7.2.1 ampsaab version page - 30/86 aeqzp0ba – combi ac1 - user manual.

  • Page 31

    7.2.2 ampseal version aeqzp0ba – combi ac1 - user manual page - 31/86.

  • Page 32

    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 that it is mandatory: this minimum outfit is listed in the steps from 1 to 8 below. Step1 connect a potentiometer in the range 0.5 to 10kohms, to modif...

  • Page 33

    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 this manual. The index may help you. 8.1 sequence for ac inverter traction setting this section of the manual describes the basic combi ac1 set-up pro...

  • Page 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.

  • Page 35: Digital Console

    9 programming & adjustments using digital console 9.1 adjustments via console adjustment of parameters and changes to the inverter’s configuration are made using the digital console. The console is connected to the cna connector of the inverter. 9.2 description of console (hand set) & connection dig...

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    9.3 description of the console menu 9.3.1 master: ampsaab version page - 36/86 aeqzp0ba – combi ac1 - user manual.

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    9.3.2 master: ampseal version aeqzp0ba – combi ac1 - user manual page - 37/86.

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    9.3.3 slave: ampsaab version page - 38/86 aeqzp0ba – combi ac1 - user manual.

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    9.3.4 slave: ampseal version aeqzp0ba – combi ac1 - user manual page - 39/86.

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    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 time the right side top and left side top buttons. Then roll until the set option item appears on the hand set display. Push the enter button. Opening zapi...

  • Page 41

    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 delay when released). - seat: cna#7 [cna#1 in ampseal] is managed as seat input (with a delay when released Æ debouncing function). 2) hour counter this op...

  • Page 42

    - none: the quick inversion function is not managed (no effect when cna#33 switches over). - timed: the quick inversion function is timed. - belly: the quick inversion function is managed but not timed. 7) set motor temperature it can be set: - analog: an analog sensor for the control of the motor t...

  • Page 43

    Trottle 0 zone 7% 11) press out ' ' ' ' % ' 12) press enter to confirm ' % ' ' ' ' 13) repeat the same from 5 to 12 points for the other adjustments 1) set battery type selects the nominal battery voltage. 2) adjust battery fine adjustment of the battery voltage measured by the controller. 3) thrott...

  • Page 44

    - 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#1 but speed reduction after 340 hours - option#3: equal to option#2 but the truck definitively stops after 380 hours 11) main cont. Voltage percentage of t...

  • Page 45

    13) the display will show main menu parameter change 1) acceler. Delay seconds. It determines the acceleration ramp. The parameter sets the time needed to speed up the traction motor from 0hz to 100hz. 2) release braking seconds. It controls the deceleration ramp when the travel request is released....

  • Page 46

    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 cna#6 in ampsaab connector, cna#29 in ampseal connector) is active. When set to 100% the speed reduction is ineffective. 13) cutback speed 3 typically from 10...

  • Page 47

    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 to 10 sec., resolution of 0.1 tiller braking sec. From 0 to 10 sec., resolution of 0.1 inversion braking sec. From 0 to 10 sec., resolution of 0.1 speed limit ...

  • Page 48

    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” functions list the tester functions are a real time feedback measurements of the state of the controller/motor/command devices. It is possible to know th...

  • Page 49

    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 when the motor temperature overtakes the motor overtemp setting. 11) accelerator from 0.0v to 5.0v. The voltage on the wiper of the accelerator (cpot on c...

  • Page 50

    - 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 (key) voltage (or it is connected to gnd), the backward travel demand is not active. 18) in 5 switch on/off. This is the level of the digital input#5 cna#2...

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    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 (or connected to gnd) the lift stop is active. - off +vb = when cna#37 is closed to a battery (key) voltage the lift stop is not active. 25) in12 switch ...

  • Page 52

    3) throttle y point this parameter, together with the throttle x point, changes the characteristic of the lift/lower accelerator input curve (see also paragraph 13.5): when the accelerator is de-pressed to x point per cent, the corresponding truck speed is y point per cent of the maximum truck speed...

  • Page 53

    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 parameter is not effective if the evp is programmed like a on/off valve. 11) max evp 0 to 100. This parameter determines the maximum voltage applied o...

  • Page 54

    9.5.4 config menu “special adjustments ” functions list 1) adjustment #1 (factory adjusted). % value. 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) ...

  • Page 55

    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 voltage it is the voltage of the motor controlled by the slave of combiac1, expressed in percentage of the maximum voltage. 3) motor power watt. Estimate va...

  • Page 56

    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 on/off : it determines if the input 7 is active or not (speed reduction #3 switch, cna#34 in ampsaab, cna#35 in ampseal). 16) digital input 8 on/off : i...

  • Page 57: 10 Other  Functions

    10 other functions 10.1 description of console “save” function the save function allows the operator to transmit the parameter values and configuration data of the controller into the console memory. It is possible to load 64 different programmes. The information saved in the console memory can then...

  • Page 58

    Press out to return to the opening zapi display ' ' ' ' % ' note: in reality the save and restore function requires the windows pc- console. 10.2 description of console “restore” function the restore param function allows transfer of the console’s stored data into the memory of the controller. This ...

  • Page 59

    Press enter for yes, or out for no ' % ' ' ' ' ' ' ' ' % ' you can see the items that are being stored in the chopper memory whilst the restore routine is happening storing acceler. Delay when finished, the console shows : main menu restore param. Press out to return to the opening zapi display ' ' ...

  • Page 60

    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 to go into the general menu ' % ' ' ' ' the display will show : main menu parameter change press roll up or roll down button until program vacc the display...

  • Page 61

    10.4 description of the throttle regulation this regulation applies a not linear relationship between the position of the accelerator and the speed of the truck. The main goal is to increase the resolution for the speed modulation when the truck is slowly moving. Three adjustments are used for the t...

  • Page 62

    10.5 description of the battery charge detection setting the battery charge detection uses two setting that specify the full charge voltage level (100%) and the discharge voltage level (10%). These two settings are the bat.Max.Adj and the bat.Min.Adj. It is possible to adapt the battery charge detec...

  • Page 63

    The battery charge detection follows this algorithm: 1) battery voltages is read when the battery current is zero, that is when the output power stage is not driven. 2) vbatt is the mean of the least samples measured by the microcontroller converter (the samples are took on key input). 3) vbatt is c...

  • Page 64

    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 that means the oldest alarm is lost when the database is full and a new alarm occurs. The logbook is composed of five locations getting possible to s...

  • Page 65

    11.2 master microcontroller alarms overview master error code related slave error code description effect machine status when the test is done restart procedure capacitor charge waiting for trac power capacitors voltage does not increase valve, pump, traction stopped, lc opened, eb applied start-up ...

  • Page 66

    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 display and roll for the alarms item. Here is the alarms list: 1) “capacitor charge” follows the charging capacitor system: when the key is switched on, t...

  • Page 67

    - 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 checks the power bridge: it turns on alternatingly the low side power mosfets and expects the phases voltage to decrease down to -batt. If the phases voltage...

  • Page 68

    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 ampsaab, can#12 in ampseal) and –batt. B) the driver circuit is damaged in the controller, which has to be replaced. 8) “contactor driver” cause: the l...

  • Page 69

    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 is probably shorted. 14) “logic failure #1” this fault is displayed when the controller detects an overvoltage or undervoltage condition. Overvoltage t...

  • Page 70

    Window around the nominal value. Troubleshooting: a) check that the controller set battery parameter value matches the battery nominal voltage. B) check that the tester menu / battery voltage parameter shows same value as the battery voltage measured with a voltmeter. If it is does not match, then d...

  • Page 71

    Troubleshooting: the problem is inside the logic of the inverter, replace the controller. 24) “no can message n5” cause: no can messages from the slave microcontroller. Troubleshooting: this alarm could be caused by a canbus malfunctioning, which blinds master-slave communication. Otherwise it is an...

  • Page 72

    11.4 master warnings overview master error code related slave error code description effect machine status when the test is done restart procedure pump warning slave has a warning slip profile error on the parameters of the slip profile setting. Traction is stopped start-up, stand-by, traction tract...

  • Page 73

    11.5 analysis and troubleshooting of master warnings 1) “pump warning” cause: the slave has a warning. Troubleshooting: connect to the slave with the hand set console and check the warning. 2) “slip profile” cause: there is an error on the choice of the parameters of the slip profile. Troubleshootin...

  • Page 74

    Troubleshooting: improve the air cooling of the controller. If the alarm is signalled when the controller is cold, the possible reasons are a thermal sensor failure or a failure in the logic card. In this case, it is necessary to replace the controller. 7) “battery low” cause: it occurs when the bat...

  • Page 75

    Troubleshooting: the alarm ends when the acquisition is done. 13) “pedal wire ko” cause: the sw continuously checks for the connection of the two supply ends of the potentiometer in the accelerator. The test consists of reading the voltage drop on a sense diode, connected between npot (cna#23 in amp...

  • Page 76

    11.6 slave alarms overview slave error code related master error code description effect machine status when the test is done restart procedure evp driver shorted waiting for node evp driver is failed shorted (always on) valve, pump, traction stopped, lc opened, eb applied start-up, stby valve or pu...

  • Page 77

    11.7 analysis and troubleshooting of slave alarms 1) “evp driver shorted” cause: the evp driver is shorted. Troubleshooting: check if there is a short or a low impedance between the negative of the coil and –batt. Otherwise the driver circuit is damaged and the controller must be replaced. 2) “pump ...

  • Page 78

    Undervoltage condition. Overvoltage threshold is 45v, undervoltage threshold is 9v in the 24v controller. In 48v controller overvoltage threshold is 65v, undervoltage threshold is 11v. Troubleshooting of fault displayed at startup or in standby; in these cases it is very likely the fault is due to a...

  • Page 79

    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 correspondant to the status of operator commands). Troubleshooting: this is a internal fault of the controller, it is necessary to replace it. 12) “watch...

  • Page 80

    11.8 slave warnings overview slave error code related master error code description effect machine status when the test is done restart procedure current sensor low pump warning pump chopper current sensor feedback too low (below 0,5v) pump motor stopped stby pump request hw fault valve pump warning...

  • Page 81

    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). Troubleshooting: this type of fault is not related to external components; replace the controller. 2) “hw fault valve” cause: the slave has detected th...

  • Page 82

    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 stuck to 0. Troubleshooting: a) check the motor connection, that there is continuity. If the motor connection is opened, the current cannot flow, so t...

  • Page 83

    14) “eep warning” cause: eeprom checksum failed troubleshooting: try to execute a clear eeprom 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 store...

  • Page 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.

  • Page 85

    12 recommended 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 manual page - 85/86.

  • Page 86

    13 periodic maintenance to be repeated at times indicated check the wear and condition of the contactors’ moving and fixed contacts. Electrical contacts should be checked every 3 months. Check the wear and condition of the electromechanical brake. According with the iso 6292 the electromechanical br...