Zapi ZAPIMOS Series, Manual

Page 1: ...s 10 3 2 Contactors 10 3 3 Fuses 10 3 4 Description of connectors Traction configuration 11 3 4 a Amp Saab connector 11 3 4 bMolexMinifitconnectors 13 3 5 Description of connectors Pump configuration...

Page 2: ...scription of Standard Console Menu 30 4 3 aTractionconfiguration 30 4 3 bPumpconfiguration 31 4 4 Functionconfiguration 32 4 4 aTraction 32 4 4 b Pump 36 4 5 Parameterregulation Tractionconfiguration...

Page 3: ...rocontroller Voltage 36 48 72 80V Maximumcurrent 36V 48V 600A RMS for 3 Maximumcurrent 72V 80V 450A RMS for 3 Booster all version 10 of maximum current for some seconds Operatingfrequency 8kHz Externa...

Page 4: ...d a voltage signal to the microprocessor when a function request for ex running request is made 2 4 b Accelerator unit The accelerator unit can consist of a potentiometer or an Hall effect device It s...

Page 5: ...shows the same relationship after signal acquisition ofthepotentiometer 2 4 c Other analog control unit 1 Input A13 Saab connector version A8 Molex Minifit version is an analog input whose typical ap...

Page 6: ...egree of protectionmeetingIP54 Protectionagainstuncontrolledmovements The main contactor will not close if ThePowerunitisnotfunctioning The Logic is not functioning perfectly the output voltage of the...

Page 7: ...overload to obtain more torque with current control The inverter can drive an electromechanical brake Hydraulicsteering function 1 tractioninverter the traction inverter sends a hydraulic steering fun...

Page 8: ...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 s...

Page 9: ...is EN50081 2 2 11 MAIN CONTACTOR AND EMERGENCY SWITCH The connection of the battery line switches must be carried out following ZAPI instruc tions If a mechanical battery line switch is installed it i...

Page 10: ...timum inverter performance the cables to the battery should be run side by side and be as short as possible 3 2 CONTACTORS The main contactor must be installed Depending on the position of a jumper in...

Page 11: ...or coil drives the load to Batt maximum current 3A A8 PLC Positive of main contactor coil A9 CM Common of FW BW SR PB SEAT BACK FW BACK BW EXCLUSIVEHYDROmicroswitches A10 KEY Connected to the power su...

Page 12: ...the customer to select the software for traction or liftingapplication Configuration MODE Open notconnected Tractioninverter MODE Close connected with A5 Pumpinverter A25 SAFETY If not connected to B...

Page 13: ...rake pedal switch activehigh A8 CPOTB Brake potentiometer wiper A9 PPOTB Brake potentiometer positive 10V output keep load 1KW A10 NPOTB Batt A11 BATT Batt A12 BACK FORW Inchingfunction forwarddirecti...

Page 14: ...N BUSvoltageI O C2 CAN L OUT LowlevelCAN BUSvoltageI O C3 CAN H HighlevelCAN BUSvoltageI O C4 CAN H OUT HighlevelCAN BUSvoltageI O D1 BATT Batt D2 MODE This input allows the customer to select the sof...

Page 15: ...hydraulic steering contactor coil drives the load to Batt maximum current 3A A8 PAUX Positiveoftheauxiliaryoutput A9 CM Common of LIFT ENABLE 1st SPEED 2nd SPEED 3rd SPEED 4th SPEED HYDRO SR microswit...

Page 16: ...ction or liftingapplication Configuration MODE Open notconnected Tractioninverter MODE Close connected with A5 Pumpinverter A25 SAFETY If not connected to Batt the MC coil power output will be disable...

Page 17: ...entiometer positive 10V output keep load 1KW A10 BATT Batt A11 BATT Batt A12 HYDROREQ Inputforhydraulicsteeringrequest Activehigh A13 SR Speed reduction input Active low switch opened A14 DIG IN This...

Page 18: ...CAN H OUT HighlevelCAN BUSvoltageI O D1 BATT Batt D2 MODE This input allows the customer to select the software for traction or liftingapplication Configuration MODE Open notconnected Tractioninverte...

Page 19: ...E4 A phase A inverted encoder with differential output E5 A22 B phase B of encoder E6 B phase B inverted encoder with differential output 2 Connection of encoder with differential outputs 5V power sup...

Page 20: ...DESCRIPTION OF POWER CONNECTIONS View of the power bars BATT Negativeofthebattery BATT Positive of the battery U V W Connection bars of the three motor phases follow this sequence and the indica tion...

Page 21: ...Page 21 3 8 AC3 MECHANICAL DRAWING...

Page 22: ...Page 22 3 9 AC4 MECHANICAL DRAWING...

Page 23: ...Page 23 3 10 CONNECTION DRAWING TRACTION CONFIGURATION 3 10 a Amp Saab connector...

Page 24: ...Page 24 3 10 b Molex Minifit connectors...

Page 25: ...Page 25 3 11 CONNECTION DRAWING PUMP CONFIGURATION 3 11 a Amp Saab connector...

Page 26: ...Page 26 3 11 b Molex Minifit connectors...

Page 27: ...Page 27 3 12 CONNECTION DRAWING COMBI CONFIGURATION 3 12 a Amp Saab connector...

Page 28: ...Page 28 3 12 b Molex Minifit connectors...

Page 29: ...to the inverter s configuration are made using the Digital Console The Console is connected to the F connector of the inverter Minifit connectorsversion 4 2 DESCRIPTION OF CONSOLE CONNECTION Digital...

Page 30: ...Page 30 4 3 DESCRIPTION OF STANDARD CONSOLE MENU 4 3 a Traction configuration...

Page 31: ...Page 31 4 3 b Pump configuration...

Page 32: ...ion inverter manages an hydraulic steering function when the key is switched ON only if the aux output 1 option is programmed as hydro contactor or as exclusive hydro 5 STOP ON RAMP ON the stop on ram...

Page 33: ...STEMENT 1 SET POT BRK MIN records the minimum value of braking pedal potentiometer when the braking pedal switch is closed the procedure is similar to the Program Vacc function see chapter 5 4 This pr...

Page 34: ...discharge table 10ADJUSTMENT 02 adjust the lower level of the battery discharge table 11 LOAD HM FROM MDI for an explanation of this point see the MDI instrument hand book 12 CHECK UP DONE for an expl...

Page 35: ...ontactor The hydraulic steering function request is also sent to the pump inverter by the can bus link The truck is electrically hold on a slope when the time set by auxiliary time parameter is elapse...

Page 36: ...action inverter So the correct programmation for the Battery check option is tractioninverter ON pumpinverter OFF 3 SETTEMPERATURE DIGITAL a digital ON OFF motor thermal sensor is connected to B6 Mini...

Page 37: ...e characteristic of the accelerator inputcurve VACC MIN and VACC MAX are values programmable by the Program Vacc function 7 ADJUSTMENT 02 adjust the upper level of the battery discharge table 8 ADJUST...

Page 38: ...NTER to go into the SET MODEL Menu 7 ThedisplaywillshowsthefirstOPTION 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 Desired OPTION appears 10 Press SET UP or SET DOWN button in o...

Page 39: ...DJUSTMENTSMenuappears 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 7 ThedisplaywillshowsSETBATTERYTYPE 8 Press ROLL UP or ROLL DOWN button until the desired param...

Page 40: ...ADJUSTMENTS menuappears 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 7 Thedisplaywillshow SETBATTERYTYPE 8 Press SET UP to choose nominal value of thebattery 9 N...

Page 41: ...enu 7 The display will show the first OPTION 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 ADJUST BATTERY appears 10 Press SET UP or SET DOWN button in order to increase or decrea...

Page 42: ...SPEEDLIMITBRAKING deceleration ramp when the pedal position is changed butnotcompletelyreleased 6 BRAKE CUTBACK determines the deceleration ramp when the speed reduction input becomes active and the...

Page 43: ...G SPEED Hz 0 2 4 6 8 10 12 14 16 18 BACKING TIME Sec 0 2 0 5 1 0 1 4 1 8 2 3 2 7 3 1 3 6 4 0 AUXILIARY TIME Sec 0 1 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 After changing a parameter press ENTER to confirm data...

Page 44: ...the parameters can be set PARAMETER PROGRAMMED LEVEL UNIT 0 1 2 3 4 5 6 7 8 9 ACCEL DELAY Sec 0 5 0 7 1 0 1 4 1 9 2 5 3 2 4 0 4 8 5 5 DECEL DELAY Sec 0 5 0 7 1 0 1 4 1 9 2 5 3 2 4 0 4 8 5 5 MAX SPEED...

Page 45: ...to go into the ParameterChangefacility 5 The Display will show the first parameter 6 Press either ROLL UP and ROLL DOWN to display the next parameter 7 The names of the Parameters appear on the Displa...

Page 46: ...witch ON OFF inchingback ON OFF 3rd speed switch ON OFF cutbackswitch ON OFF 4th speed switch ON OFF brakeswitch ON OFF hydro speed req ON OFF seatswitch ON OFF voltage booster V exclusivehydro ON OFF...

Page 47: ...en the accelerator microswitch is closed Increase the Level accordingly 8 Set the Speed Reductions as required Make adjustments to CUTBACK SPEED Check the performance with the accelerator pedal totall...

Page 48: ...PERATURE this is the temperature of the motor if the option is pro grammed None see chapter 4 4 a it shows 0 8 ACCELERATOR the voltage of the accelerator potentiometer s wiper CPOT The voltage level i...

Page 49: ...h ON GND active entry of Handbrake Switch open switch OFF VB non active entry of microswitch closed switch 18 VOLTAGE BOOSTER this is the booster of the voltage supplied to the motor in load condition...

Page 50: ...OSFET devices 7 MOTOR TEMPERATURE this is the temperature of the motor if the option is pro grammed None see chapter 4 4 b it shows 0 8 ACCELERATOR the voltage of the accelerator potentiometer s wiper...

Page 51: ...ER function of the Digital Console 1 Opening Zapi Display 2 Press ENTER to go into the General menu 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until TESTER MENU appear on the display...

Page 52: ...t showing how to use the SAVE function of the Digital Console 1 Opening Zapi Display 2 Press ENTER to go into the General menu 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until SAVE PA...

Page 53: ...ing how to use the RESTORE function of the Digital Console 1 Opening Zapi Display 2 Press ENTER to go into the General menu 3 The Display will show 4 Press ROLL UP or ROLL DOWN buttonuntil RESTORE PAR...

Page 54: ...pening Zapi Display 2 Press ENTER to go into the General menu 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display 5 TheDisplaywillshow 6 Press ENT...

Page 55: ...tton until PROGRAM VACC appears on the display 5 The Display will show 6 Press ENTER to go into the PROGRAM VACC routine 7 The Display will show the minimum and maximum valuesofpotentiometerwiperoutpu...

Page 56: ...RMS DISPLAYED ON CONSOLE 1 WATCH DOG The test is made in both running and standby It is a self diagnosing test within the logic If an alarm should occur replace the logic 2 EEPROM KO Fault in the area...

Page 57: ...b runningmicroswitchfailure c incorrectoperation d if the defect persists replace the logic 9 HANDBRAKE The truck does not start because the handbrake switch is opened Possible causes a defectivewirin...

Page 58: ...eplace the logic if the defect persists replace the power unit 15 MAINCONTACTORALARMS COIL SHORTED When the key is switched ON the P checks the MC driver FF SR If it does not react in a correct way to...

Page 59: ...range of inverter temperature sensor is always checked and a warning is signalled if it is out of range When this alarm is signalled check the connection of the sensors 20 WAITINGPUMP This alarm is pr...

Page 60: ...S OF ALARMS DISPLAYED ON CONSOLE 1 WATCH DOG The test is made in both running and standby It is a self diagnosing test within the logic If an alarm should occur replace the logic 2 EEPROM KO Fault in...

Page 61: ...not closed Possible reasons a check if the charging resistance is opened b The charging circuit has a failure c There is a problem on the power modules 8 VMNLOW VMNHIGH The test is carried out during...

Page 62: ...driver is not shorted if it is this alarm is signalled replace the logic board CONTACTOR DRIVER When the initial diagnosis is finished the traction logic closes the MC and checks the voltage on the D...

Page 63: ...sis of the CAN BUS line is present only if the inverter uses this link de pends on the software version It is signalled if the inverter does not receive any mes sage from the CAN BUS line First of all...

Page 64: ...PARTS FOR INVERTER Part Number Description C16507 Protected 500A strip Fuse C16505 Protected 355A strip Fuse C16520 6 3A 20mm Control Circuit Fuse C29509 SW 200 80V Single Pole Contactor C29532 SW 20...

Page 65: ...level Check every 3 months Check the mechanical operation of the Contactor s Moving contacts should be free to movewithoutrestriction Check every 3 months Checks should be carried out by qualified pe...

Page 66: ...AC3 AC4 INVERTER OPERATINGHANDBOOK ANDFUNCTIONDESCRIPTION ELECTRONICINDUSTRIALDEVICES 42028 POVIGLIO R E Via Parma 59 ITALIA Tel 39 0522 960050 r a Fax 39 0522 960259 e mail zapi zapispa it...