Zapi AC-2 User manual

ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel [phone] (r.a.) – Fax [phone]
e-mail: [email protected] – web: www.zapispa.it
EN
User Manual
AC-2
INVERTER

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 damage caused
by the improper use of the present publication and of the device/devices described in it.
Zapi spa reserves the right to make 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 therefore does not reflect any changes in the characteristics of the
product as a result of updating.
is a registered trademark property of Zapi S.p.A.
NOTES LEGEND
4The symbol aboard is used inside this publication to indicate an annotation or a
suggestion you should pay attention.
UThe symbol aboard is used inside this publication to indicate an action or acharacteristic very important as for security. Pay special attention to the
annotations pointed out with this symbol.
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Contents
1INTRODUCTION ...................................................................................................................5
2SPECIFICATION...................................................................................................................6
2.1 Technical specifications..............................................................................................6
2.2 Block diagram.............................................................................................................6
2.3 Control unit .................................................................................................................6
2.3.1 Microswitches ...............................................................................................6
2.3.2 Accelerator unit.............................................................................................7
2.3.3 Other analog control unit...............................................................................7
2.3.4 Speed feedback............................................................................................8
2.4 UProtection features .................................................................................................8
2.5 Operational features...................................................................................................8
2.6 Diagnosis....................................................................................................................9
2.7 Thermal consideration..............................................................................................10
2.8 UGeneral instructions and precautions...................................................................10
2.9 USusceptibility and electromagnetic emission........................................................10
2.10 Main contactor and emergency switch .....................................................................10
3USAFETY AND PROTECTION.......................................................................................12
4INSTALLATION...................................................................................................................13
4.1 Connection cables....................................................................................................13
4.2 Contactors ................................................................................................................13
4.3 Fuses........................................................................................................................13
4.4 Description of connectors - Traction configuration ..................................................14
4.5 Description of connectors - Pump configuration.......................................................16
4.6 Encoder installation ..................................................................................................18
4.7 Description of power connections.............................................................................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
5PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE...................................25
5.1 Adjustments via Console..........................................................................................25
5.2 Description of Console & Connection.......................................................................25
5.3 Description of Standard Console Menu....................................................................26
5.3.1 Traction configuration .................................................................................26
5.3.2 Pump configuration.....................................................................................27
5.4 Function configuration ..............................................................................................27
5.4.1 Traction.......................................................................................................27
5.4.2 Pump...........................................................................................................31
5.5 Parameter regulation: Traction configuration............................................................38
5.6 Parameter regulation: Pump configuration...............................................................39
5.7 Programming console functions ...............................................................................41
5.8 Sequence for Ac Inverter Traction setting ................................................................42
5.9 Sequence for Ac Inverter Pump setting....................................................................43
5.10 Tester: description of the function; Traction configuration........................................43
5.11 Tester: description of the function; Pump configuration............................................45
6OTHER FUNCTIONS ..........................................................................................................48
6.1 Description of the Console “SAVE” function.............................................................48
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6.2 Description of Console “RESTORE” function...........................................................50
6.3 Description of “ALARMS” menu ...............................................................................52
6.4 Description of Console “PROGRAM VACC” function...............................................53
7AC-2 INVERTER DIAGNOSTIC - TRACTION CONFIGURATION ....................................55
7.1 Analysis of alarms displayed on console..................................................................55
8AC-2 INVERTER DIAGNOSTIC - PUMP CONFIGURATION.............................................59
8.1 Analysis of alarms displayed on console..................................................................59
9RECOMMENDED SPARE PARTS FOR INVERTER .........................................................63
10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED.........................64
APPROVAL SIGNS
COMPANY FUNCTION INITIALS SIGN
GRAPHIC AND LAYOUT CP
PROJECT MANAGER FG
TECHNICAL ELECTRONIC
MANAGER VISA PP
SALES MANAGER VISA PN
Publication N°: ADEZP0AE
Edition: July 2006
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1 INTRODUCTION
Within the ZAPIMOS family, 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.
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2 SPECIFICATION
2.1 Technical specifications
Inverter for AC asynchronous 3-phase motors
Regenerative braking functions
Can-bus interface
Digital control based upon a microcontroller
Voltage:.......................................................................24 - 36 - 48 - 72 – 80 – 96 V
Maximum current (24 V, 36 V):.................................................. 450 A (RMS) for 3'
Maximum current (36 V, 48 V):.................................................. 350 A (RMS) for 3'
Maximum current (72 V, 80 V):.................................................. 275 A (RMS) for 3'
Maximum current (96 V): ...........................................................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 diagram
2.3 Control unit
2.3.1 Microswitches
- The microswitches must have a contact resistance lower than 0.1 Ωand a
leakage current lower than 100 µA.
- When full load connected, the voltage drop between the key switch contacts
must be lower than 0.1 V.
- The microswitches send a voltage signal to the microprocessor when a
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function request (for ex.: running request) is made.
2.3.2 Accelerator unit
The accelerator unit can consist of a potentiometer or an Hall effect device.
It should be in a 3-wire configuration.
CPOT (E1) signal ranges from 0 to 10 V.
Potentiometer value should be in the 0.5 – 10 kohm range; generally, the load
should be in the 1.5 mA to 30 mA range. Faults can occur if it is outside this
range.
The Procedure for automatic potentiometer signal acquisition is carried out using
the Console. This enables adjustment of the minimum and maximum useful
signal level (PROGRAM VACC function), in either direction. This function is
unique when it is necessary to compensate for asymmetry with the mechanical
elements associated with the potentiometer, especially relating to the minimum
level.
The sequence of procedure 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 indicate the point
where the direction switches close. 0 represents the mechanical zero of the
rotation.
The Left Hand graph shows the relationship of the motor voltage without signal
acquisition being made. The Right Hand Graph shows the same relationship after
signal acquisition of the potentiometer.
2.3.3 Other analog control unit
1) Input E8 is an analog input, whose typical application is for proportional
braking. It should be in a 3 wire configuration. Potentiometer value should be
in the 0.5-10 kΩrange. Generally, the load should be in the 1.5 mA to 30 mA
range.
The CPOTB (E8) signal range is from 0 to 10 V.
2) Connections F6 (PTHERM) and F12 (NTHERM) are used for a motor thermal
sensor. It can be digital (on/off sensor, normally closed) or analog. See also
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chapter 5.4 for more explanation.
2.3.4 Speed feedback
The motor control is based upon the motor speed feedback. The speed
transducer is an incremental encoder, with two phases shifted at 90°. The
encoder can be of different types:
- power supply: +5 V or +12 V
- electric output: open collector ( NPN or PNP), push-pull, line driver
- standard (A and B) or differential )BB,,A(A, output.
For more details about encoder installation see also chapter 4.6.
2.4 UProtection features
1) Battery polarity inversion
It is necessary to fit a MAIN CONTACTOR to protect the inverter against
reverse battery polarity and for safety reasons.
2) Connection Errors
All inputs are protected against connection errors.
3) Thermal protection
If the controller temperature exceeds 75 °C, the maximum current is reduced
in proportion to the thermal increase. The temperature can never exceeds
100 °C.
4) External agents
The inverter is protected against dust and the spray of liquid to a degree of
protection 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 accelerator does not fall below the minimum
voltage value stored, with 1 V added.
- Running microswitch in closed position.
6) Low battery charge
When the battery charge is low, the maximum current is reduced to the half
of the maximum current programmed.
7) Protection against accidental Start up
A precise sequence of operations are necessary before the machine will
start.
Operation cannot begin if these operations are not carried out correctly.
Requests for drive, must be made after closing the key switch.
2.5 Operational features
- Speed control.
- Optimum behaviour an a slope due to the speed feedback:
- 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
electrically hold on a slope) for a programmable time (see also chapter
5.4).
- Stable speed in every position of the accelerator.
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- Regenerative release braking based upon deceleration ramps.
- Regenerative braking when the accelerator pedal is partially released
(deceleration).
- Direction inversion with regenerative braking based upon deceleration ramp.
- Regenerative braking and direction inversion without contactors: only the
main contactor is present.
- The release braking ramp can be modulated by an analog input, so that a
proportional brake feature is obtained.
- Optimum sensitivity at low speeds.
- Voltage boost at the start and with overload to obtain more torque (with
current control).
- The inverter can drive an electromechanical brake.
- Hydraulic steering function:
1) traction inverter
- the traction inverter sends a "hydraulic steering function" request to
the pump inverter on the can-bus line (see also OPTION chapter
5.4).
- moreover, if the pump inverter is not present (for ex: tractor
application), the traction inverter can manage an "hydraulic steering
function" by driving a hydro contactor which drive a hydraulic steering
motor (output F9), see also OPTION chapter.
2) pump inverter
- the pump inverter manage an "hydraulic steering function". That is, it
drives the pump motor at the programmed speed for the
programmed 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 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 on the console.
- Test function within console for checking main parameters.
2.6 Diagnosis
The microcontroller continually monitors the inverter and carries out a diagnostic
procedure on the main functions. The diagnosis is made in 4 points:
1) Diagnosis on key switch closing that checks: watchdog circuit, current
sensor, capacitor charging, phase's voltages, contactor drives, can-bus
interface, if the switch sequence for operation is correct and if the output of
accelerator unit is correct.
2) Standby diagnosis in stby that checks: watchdog circuit, phase's voltages,
contactor driver, current sensor, can-bus interface.
3) Diagnosis during operation that checks: watchdog circuits, contactor driver,
current sensors, can-bus interface.
4) Continuous diagnosis that check: temperature of the inverter, motor
temperature.
Diagnosis is provided in two ways. The digital console can be used, which gives
a detailed information about the failure; the failure code is also sent on the Can-
Bus.
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2.7 Thermal consideration
- The heat generated by the power block must be dissipated. For this to be
possible, the compartment must be ventilated and the heat sink materials
ample.
- The heat sink material and system should be sized on the performance
requirement of the machine. Abnormal ambient air temperatures should be
considered. In situations where either ventilation is poor, or heat exchange is
difficult, forced air ventilation should be used.
- The thermal energy dissipated by the power block module varies and is
dependent on the current drawn and the duty cycle.
2.8 UGeneral instructions and precautions
- Never connect SCR low frequency chopper with ASYNCHRONOUS
INVERTER because the ASYNCHRONOUS filter capacitors alter the SCR
choppers' work. If it is necessary to use two or more control units (traction +
lift. for ex.), they must belong to the ZAPIMOS family.
- Do not connect the inverter to a battery with a nominal value different from
the value indicated on the controller plate. If the battery value is greater, the
power section may fail; if it is lower, the control unit does not "power up".
- During battery charge, disconnect 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, in order to avoid dangerous situations due to connection errors.
- After the controller is switched off (key off), the filter capacitor remains
charged for some minutes; if you need to work on the inverter, discharge
them using a 10 ÷ 100 ohm resistance connected from the +Batt to the -Batt.
2.9 USusceptibility and electromagnetic emission
Electromagnetic susceptibility and emission are strongly influenced by the
installation. Special attention must be given to the lengths and the paths of the
electric connections and the shields.
This situation is beyond ZAPI's control. Therefore ZAPI declines any
responsibility for non-compliance if correct testing is not made (the irradiated
emission directive is EN50081-2).
2.10Main contactor and emergency switch
- The connection of the battery line switches must be carried out following
ZAPI instructions.
- If a mechanical battery line switch is installed, it is necessary that the key
supply to the inverter is open together with power battery line; if not, the
inverter may be damaged if the switch is opened during a regenerative
braking.
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- An intrinsic protection is present inside 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.
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3 USAFETY AND PROTECTION
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 carefully designed.
AC-2 inverter electronic implements an hardware safety circuit, which is able to
open the Line Contactor (LC) and the Electric Brake (EB) - and therefore to cut
the power line stopping the machine via HARDWARE, that is bypassing the
software control of the LC and EB. This safety circuit is driven by "SAFETY" input
(see next chapter). If safety input is connected to -BATT, the "SAFETY" circuit is
inactive; if the input is open, the "SAFETY" circuit becomes active and, within a
timeout, it is able to open the drivers of LC coil and EB coil. The safety circuit is
also periodically checked by the AC-2 microcontroller; if the microcontroller
detects a failure in 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 "SEAT" microswitch or to the "DEADMAN" microswitch (it depends on the
application); in this way the machine will be brought to a safe status as soon as
the operator leaves the machine.
- COMBI CONFIGURATION: in this case the pump controller acts as
supervisor, checking the traction controller functionality by the CANBUS. So it is
suggested to connect the "SAFETY" input of traction controller to a dedicated
output of pump controller, so that the pump controller can drive the traction safety
input and open the power line in case of malfunctioning of traction controller.
ZAPI is always available to cooperate with the customer in order to evaluate
installation and connection solutions. Furthermore, ZAPI is available to
develop new SW or HW solutions to improve the safety of the machine,
according to customer requirements.
Machine manufacturer holds the responsibility for the truck safety features
and related approval.
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4 INSTALLATION
Install the controller with the base-plate on a flat metallic surface that is clean and
unpainted. Apply a light layer of thermo-conductive grease between the two
surfaces to permit better heat dissipation.
Ensure that the wiring of the cable terminals and connectors is carried out
correctly.
Fit transient suppression devices to the horn, solenoid valves, and contactors not
connected to the controller.
4.1 Connection cables
For the auxiliary circuits, use cables of 0.5 mm² section.
For power connections to the motor and to the battery, use cables having section
of 35 mm² (as a minimum).
For the optimum inverter performance, the cables to the battery should be 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 contactor coil is on/off (the coil is driven with
the full battery voltage).
- the output which drives the main contactor coil is switched at high frequency
(1kHz) with a duty cycle of 70%; this feature is useful to decrease the power
dissipation of the contactor coil.
4.3 Fuses
- Use a 6.3 A Fuse for protection of the auxiliary circuits.
- For protection of the power unit, refer to diagrams. The Fuse value shown is
the maximum allowable. For special applications or requirements these
values can be reduced.
- For Safety reasons, we recommend the use of protected fuses in order to
prevent the spread of fused particles should the fuse blow.
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4.4 Description of connectors - Traction configuration
A1 PCLRXD Positive serial reception.
A2 NCLRXD Negative serial reception.
A3 PCLTXD Positive serial transmission.
A4 NCLTXD Negative serial transmission.
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 the Flash memory
programming (if used).
B1 -BATT -Batt.
B2 MODE This input allows the customer to select the software
for traction or lifting application.
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Configuration:
MODE: Open (not connected) Traction inverter
MODE: Close (connected with A5) Pump inverter
C1 CAN-L Low level CAN-BUS voltage I/O.
C2 CAN-L-OUT Low level CAN-BUS voltage I/O.
C3 CAN-H High level CAN-BUS voltage I/O.
C4 CAN-H-OUT High level 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 kΩ.
E3 NPOT Negative of accelerator unit, tested for wire
disconnection diagnosis.
E4 CM Common of FW / BW / SR / PB / SEAT / BACK. FW /
BACK. BW / EXCLUSIVE HYDRO / ENABLE
microswitches.
E5 FORW Forward direction request input. It must be connected
to the forward direction microswitch, active high.
E6 BACK Backward direction request input. It must be connected
to the backward direction microswitch, active high.
E7 PB Brake request input. It must be connected to the brake
pedal switch, active high.
E8 CPOTB Brake potentiometer wiper.
E9 PPOTB Brake potentiometer positive. 10 V output; keep load >
1 kΩ.
E10 NPOTB -Batt.
E11 -BATT -Batt.
E12 BACK. FORW Inching function, forward direction input. It must be
connected to the inching forward switch. Active high.
E13 BACK. BACK Inching function, reverse direction input. It must be
connected to the inching reverse switch. Active high.
E14 EX. HYDRO/ENABLE Exclusive hydro or accelerator enable function
input. It must be connected to the exclusive hydro
microswitch or to the accelerator enable switch. Active
high (see also OPTION chapter).
F1 KEY Connected to the power supply through a microswitch
(CH) with a 10 A fuse in series.
F2 PLC Positive of main contactor coil.
F3 PBRAKE Positive of the electromechanical brake coil.
F4 SEAT SEAT input; it must be connected to the SEAT
microswitch; it is active high.
F5 SAFETY If not connected to -Batt the MC coil power output will
be disabled. It can also be used as a general purpose
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input.
F6 PTHERM Input for motor temperature sensor.
F7 CM Common of FW / BW / SR / PB / SEAT / INCHING FW
/ INCHING BW / EXCLUSIVE HYDRO / ENABLE
microswitches.
F8 NLC Negative of 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 (switch
opened). See also OPTION chapter.
F11 GND -Batt.
F12 NTHERM -Batt.
4.5 Description of connectors - Pump configuration
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A1 PCLRXD Positive serial reception.
A2 NCLRXD Negative serial reception.
A3 PCLTXD Positive serial transmission.
A4 NCLTXD Negative serial transmission.
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 the Flash memory
programming (if used).
B1 -BATT -Batt.
B2 MODE This input allows the customer to select the software
for traction or lifting application.
Configuration:
MODE: Open (not connected) Traction inverter
MODE: Close (connected with B1) Pump inverter
C1 CAN-L Low level CAN-BUS voltage I/O.
C2 CAN-L-OUT Low level CAN-BUS voltage I/O.
C3 CAN-H High level CAN-BUS voltage I/O.
C4 CAN-H-OUT High level 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 kΩ.
E3 NPOT Negative of accelerator unit, tested for wire
disconnection diagnosis.
E4 CM Common of LIFT ENABLE / 1st SPEED / 2nd SPEED /
3rd SPEED / 4th SPEED / HYDRO / SR
microswitches.
E5 LIFT ENABLE Input for potentiometer lifting enable input; it is active
HIGH.
E6 1st SPEED Input for first speed request; it is active HIGH.
E7 3rd SPEED Input for third speed request; it is active HIGH.
E8 AN. IN. Free analog input.
E9 PPOT Potentiometer positive: 10 V output; keep load > 1kΩ.
E10 -BATT -Batt.
E11 -BATT -Batt.
E12 HYDRO REQ. Input for hydraulic steering request. Active high.
E13 SR Speed reduction input. Active low (switch opened).
E14 DIG. IN. This is a digital input, free for customer request.
F1 KEY Connected to the power supply through a microswitch
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(CH) with a 10 A fuse in series.
F2 PAUX Positive of the auxiliary output.
F3 PHYDRO Positive for the hydraulic steering contactor.
F4 4th SPEED Input for fourth speed request; it is active HIGH.
F5 SAFETY If not connected to -Batt the MC coil power output will
be disabled. It can also be used as a general purpose
input.
F6 PTHERM Input for motor temperature sensor.
F7 CM Common of LIFT ENABLE / 1st SPEED / 2nd SPEED /
3rd SPEED / 4th SPEED / HYDRO / SR
microswitches.
F8 NAUX This output can be used for drive the main contactor
coil (single pump configuration) or to drive an auxiliary
load (combi configuration)
F9 NHYDRO Output for driving an hydraulic steering contactor; 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 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 +12 V. It can have
different electronic output.
D1 +5 V/+12 Vpositive of encoder power supply.
D2 GND negative of encoder power supply.
D3 A phase A of encoder.
D4
A
phase A inverted (encoder with differential output).
D5 B phase B of encoder.
D6 Bphase B inverted (encoder with differential output).
2) Connection of encoder with differential outputs; +5 V power supply.
3) Connection of encoder with open collector output; +5 V power supply.
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4) Connection of encoder with open collector output: +12 V power supply.
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.
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4.7 Description of power connections
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.
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