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EQUIPMENTS CONSTRUCTION
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e-mail: zapi@zapispa.it web: www.zapispa.it
EN
User Manual
DUALAC2/
&HP/POWER
INVERTER
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.
NOTES LEGEND
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Contents
1
2
5
6
INTRODUCTION ...................................................................................................................6
SPECIFICATION ...................................................................................................................7
2.1
Technical specifications - "Dualac2" ...........................................................................7
2.1.1
Block diagram ...............................................................................................7
2.2
Technical specifications - "Dualac2&hp".....................................................................8
2.2.1
Block diagram ...............................................................................................8
2.2.2
Chopper block diagram.................................................................................9
2.3
Technical specifications - "Dualac2 Power"................................................................9
2.3.1
Block diagram ...............................................................................................9
2.4
Technical specifications - "Dualac2&hp Power" .........................................................9
2.4.1
Block diagram .............................................................................................10
SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT.....11
3.1
Microswitches ...........................................................................................................11
3.2
Accelerator unit.........................................................................................................11
3.3
Other analog control unit ..........................................................................................12
3.4
Speed feedback........................................................................................................12
3.5
Steering angle transducer.........................................................................................12
INSTALLATION HINTS.......................................................................................................15
4.1
Material overview......................................................................................................15
4.1.1
Connection cables ......................................................................................15
4.1.2
Contactors...................................................................................................15
4.1.3
Fuses ..........................................................................................................15
4.2
Installation of the hardware.......................................................................................15
4.2.1
Positioning and cooling of the controller .....................................................16
4.2.2
Wirings: power cables.................................................................................16
4.2.3
Wirings: CAN connections and possible interferences ...............................16
4.2.4
Wirings: I/O connections .............................................................................19
4.2.5
Encoder installation.....................................................................................19
4.2.6
Main contactor and key connection ............................................................20
4.2.7
Insulation of truck frame..............................................................................20
4.3
Protection and safety features ..................................................................................20
4.3.1
Protection features......................................................................................20
4.3.2
Safety Features...........................................................................................21
4.4
EMC..........................................................................................................................21
4.5
Various suggestions .................................................................................................23
OPERATIONAL FEATURES ..............................................................................................24
5.1
Diagnosis ..................................................................................................................24
DESCRIPTION OF THE CONNECTORS............................................................................26
6.1
Connectors of the logic - "Dualac2" and "Dualac2 Power" ......................................26
6.2
Connectors of the logic - "Dualac2&hp" and "Dualac2&hp Power" .........................28
6.3
CANBUS connector description................................................................................30
6.3.1
"Dualac2" Controller in stand-alone configuration ......................................30
6.3.2
"Dualac2" Controller is a termination module in the canbus net .................31
6.3.3
"Dualac2" Controller is a repetition module in the canbus net ....................31
6.4
Description of power connections.............................................................................32
6.4.1
"Dualac2" ....................................................................................................32
6.4.2
"Dualac2 Power" .........................................................................................33
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6.4.3
"Dualac2&hp" ............................................................................................. 34
6.4.4
"Dualac2&hp Power" .................................................................................. 36
7
DRAWINGS......................................................................................................................... 38
7.1
Mechanical drawing.................................................................................................. 38
7.1.1
Dimensions of "Dualac2" ............................................................................ 38
7.1.2
Dimensions of "Dualac2 Power"................................................................. 39
7.1.3
Dimensions of "Dualac2&hp"...................................................................... 40
7.1.4
Dimensions of "Dualac2&hp Power" ......................................................... 41
7.2
Connection drawing - "Dualac2" and "Dualac2 Power" standalone ......................... 42
7.3
Connection drawing - "Dualac2&hp" and "Dualac2&hp Power" standalone ............ 43
8
PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE .................................. 44
8.1
Adjustments via Console .......................................................................................... 44
8.2
Description of Console & Connection....................................................................... 44
8.3
Description of Standard Console Menu.................................................................... 45
8.3.1
"Dualac2" and "Dualac2 Power" menu configuration ................................. 45
8.3.2
"Dualac2&hp" and "Dualac2&hp Power" menu configuration..................... 47
8.4
Function configuration .............................................................................................. 49
8.4.1
"Dualac2" and "Dualac2 Power" - Master................................................... 49
8.4.2
"Dualac2" and "Dualac2 Power" - Slave..................................................... 52
8.4.3
"Dualac2&hp" and "Dualac2&hp Power" - Master ...................................... 52
8.4.4
"Dualac2&hp" and "Dualac2&hp Power" - Slave ........................................ 52
8.5
Parameter regulation................................................................................................ 58
8.5.1
"Dualac2" - Master...................................................................................... 58
8.5.2
"Dualac2" - Slave........................................................................................ 60
8.5.3
"Dualac2&hp" Master .............................................................................. 60
8.5.4
"Dualac2&hp" - Slave ................................................................................. 60
8.6
Programming console functions ............................................................................... 65
8.6.1
"Dualac2" and "Dualac2 Power" ................................................................. 65
8.6.2
"Dualac2&hp" and "Dualac2&hp Power" .................................................... 65
8.7
Sequence for Ac Traction Inverter setting ................................................................ 66
8.8
Sequence for Dc Pump Chopper setting (DUALAC&HP only) ................................. 67
8.9
Tester: description of the function ............................................................................ 68
8.9.1
"Dualac2" and "Dualac2 Power" - Master................................................... 68
8.9.2
"Dualac2" and "Dualac2 Power" - Slave..................................................... 69
8.9.3
"Dualac2&hp" and "Dualac2&hp Power" Master ..................................... 70
8.9.4
"Dualac2&hp" and "Dualac2&hp Power" - Slave ........................................ 70
9
OTHER FUNCTIONS .......................................................................................................... 73
9.1
Save and Restore function ....................................................................................... 73
9.2
Description of Alarms menu ..................................................................................... 73
9.3
Description of Console Program Vacc function ........................................................ 74
10 "DUALAC2" AND "DUALAC2&HP" INVERTER DIAGNOSTIC ....................................... 76
10.1 Traction related fault codes ...................................................................................... 76
10.2 Analysis of traction related alarms displayed on console ......................................... 81
10.3 Pump related fault codes.......................................................................................... 85
10.4 Analysis of pump related alarms displayed on console............................................ 86
11 RECOMMENDED SPARE PARTS FOR INVERTER ......................................................... 88
12 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......................... 89
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APPROVAL SIGNS
COMPANY FUNCTION
INITIALS
FF
PROJECT MANAGER
FG
TECHNICAL ELECTRONIC
MANAGER VISA
PP
PN
SIGN
Publication N: AE9ZP0BD
Edition: December 2006
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1 INTRODUCTION
Within the ZAPIMOS family, the DUALAC2 inverter is the model suitable for
control of pairs of 3.0kW to 7.0kW motors. The DUALAC2&HP can also control a
DC-Series pump motor, up to 15kW. These controllers have been expressly
designed for battery powered applications, traction and hydraulic functions. They
are fit for electric trucks, utility cars, tractors.
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2 SPECIFICATION
2.1 Technical specifications - "Dualac2"
Inverter for pairs of AC asynchronous 3-phase motors
Regenerative braking functions
Can-bus interface
Flash memory (256 Kbytes On-Chip Program Memory, each microcontroller)
Digital control based upon a microcontroller (one per each motor)
Voltage: ...............................................................................24 - 36 - 48 - 72 80 V
Maximum current (24 V):...................................350 A (RMS) for 3' per each motor
Maximum current (36/48 V):..............................320 A (RMS) for 3' per each motor
Maximum current (72/80 V):..............................300 A (RMS) for 2' per each motor
Operating frequency:...................................................................................... 8 kHz
External temperature range: ............................................................ -30 C 40 C
Maximum inverter temperature (at full power): ...............................................75 C
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3.1 Microswitches
-
The microswitches must have a contact resistance lower than 0.1 ohm and a
leakage current lower than 100 A.
When full load connected, the voltage between the key switch contacts must
be lower than 0.1 V.
The microswitches send a voltage signal to the microprocessor when a
function request (for ex.: running request) is made.
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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.
positive supply: 5 V or 10 V;
potentiometer has to be installed in a way that in the "zero" position (straight
wheels), poti output voltage is in the middle of the electric range
corresponding to a full left-to-right transition of the steered wheels;
install the potentiometer in a way that, when truck turns right, poti output
voltage increases;
use "SET STEER MIN" and "SET STEER MAX" functions to record the
extremes (minimum and maximum) of the potentiometer range; see chapter
8.4.
use "SET STEER 0-POS" function to record the poti output when the steered
wheels are straight; see chapter 8.4.
Potentiometer connections
Steering table
The relationship between the two motors speed changes as a function of the
steering angle and of the axle/wheeltrack ratio.
While the steering angle is an information coming from the transducer
AE9ZP0BD - DUALAC2/&HP/POWER - User Manual
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The relationship between the two motors speed is equal to the relationship
between the two radius described during the curve.
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4 INSTALLATION HINTS
In the description of these installation suggestions you will find some boxes of
different colours, they mean:
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4.1.2 Contactors
The main contactor must be installed. The LC coil driver is voltage controlled by
means of a 1 kHz PWM. The voltage applied to the coil can be adjusted by "Main
Cont Voltage" parameter in Config/Adjustment menu. It has to be adjusted to the
LC coil nominal voltage.
4.1.3 Fuses
-
Before doing any operation, ensure that the battery is disconnected and
when all the installation is completed start the machine with the drive
wheels raised from the floor to ensure that any installation error do not
compromise safety.
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After operation, even with the Key Switch open, the internal capacitors may
remain charged for some time. For safe operation, we recommend that the
battery is disconnected, and a short circuit is made between Battery
Positive and Battery Negative power terminals of the inverter using a
Resistor between 10 ohm and 100 ohm.
Install the inverter 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 such as those for activating the pump motor.
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.
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CAN stands for Controller Area Network. 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 industry to
permit communication among the various electronic modules of a vehicle,
connected as illustrated in this image:
The best cable for can connections is the twisted pair; if it is necessary to
increase the immunity of the system to disturbances, a good choice would
be to use a cable with a shield connected to the frame of the truck.
Sometimes it is sufficient a simple double wire cable or a duplex cable not
shielded.
In a system like an industrial truck, where power cables carry hundreds of
Ampere, there are voltage drops due to the impedance of the cables, and
that could cause errors on the data transmitted through the can wires. In the
following figures there is an overview of wrong and right layouts of the cables
routing.
Wrong Layout:
R
Can Bus
Power cables
Module
1
Module
2
Module
3
R
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Correct Layout:
R
Can Bus
Power cables
Module
1
Module
2
Module
3
R
The chain starts from the BATT post of the controller that works with the
highest current, and the others are connected in a decreasing order of power.
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).
Correct Layout:
R
Can Bus
Power cables
Module
1
Module
2
Center of the Ground connection
Module
3
R
In this case the power cables starting from the two similar controllers must be as
short as possible. Of course also the diameter of the cable concurs in the voltage
drops described before (higher diameter means lower impedance), so in this last
example the cable between the minus of the Battery and the common ground
point (pointed by the arrow in the image) must be dimensioned taking into
account thermal and voltage drop problems.
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Can advantages
The complexity of today systems needs more and more data, signal and
information must flow from a node to another. CAN is the solution to different
problems that arise from this complexity
- simplified design (readily available, multi sourced components and tools)
AE9ZP0BD - DUALAC2/&HP/POWER - User Manual
After crimping the cable, verify that all strands are entrapped in the wire
barrel.
Verify that all the crimped contacts are completely inserted on the connector
cavities.
A cable connected to the wrong pin can lead to short circuits and failure;
so, before turning on the truck for the first time, verify with a multimeter the
continuity between the starting point and the end of a signal wire.
For information about the mating connector pin assignment see the
paragraph description of the connectors.
+5V/+12V
GND
A
B
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
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The connection of the main contactor can be carried out following the
drawing in the figure.
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.
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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External agents:
The inverter is protected against dust and the spray of liquid to a degree of
protection meeting IP65.
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.
Low battery charge:
When the battery charge is low, the maximum current is reduced to the half
of the maximum current programmed.
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.
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Dualac2 controller electronic implements double hardware circuit for four Digital
inputs: Seat (C5), Forward (C6), Reverse (C7), Accelerator Enable (C8) and one
Analog input: CPOT (C21).
These signals are input, through two independent hardware circuits, to both
microcontrollers which implement a cross-check of the inputs status, thus
preventing an abnormal behaviour due to a failure in the input hardware.
It is strongly suggested to connect the machine safety related devices to these
five inputs, in order to increase machine safety.
4.4 EMC
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EMC stands for Electromagnetic Compatibility, and it represents the studies and
the tests on the electromagnetical energy generated or received by an electrical
device.
So the analysis works in two directions:
1) The study of the emission problems, the disturbances generated by the
device and the possible countermeasure to prevent the propagation of that
energy; we talk about conduction issues when guiding structures such as
wires and cables are involved, radiated emissions issues when it is studied
the propagation of electromagnetic energy through the open space. In our
case the origin of the disturbances can be found inside the controller with the
switching of the mosfets which are working at high frequency and generate
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 cables
and their shielding can solve the majority of the emission problems.
2) The study of the immunity can be divided in two main branches: protection
from electromagnetic fields and from electrostatic discharge.
The electromagnetic immunity concern the susceptibility of the controller
with regard to electromagnetic fields and their influence on the correct work
made by the electronic device.
There are well defined tests which the machine has to be exposed to.
These tests are carried out at determined levels of electromagnetic fields, to
simulate external undesired disturbances and verify the electronic devices
response.
3) The second type of immunity, ESD, concerns the prevention of the effects of
electric current due to excessive electric charge stored in an object. In fact,
when a charge is created on a material and it remains there, it becomes an
electrostatic charge; ESD happens when there is a rapid transfer from a
charged object to another. This rapid transfer has, in turn, two important
effects:
A) this rapid charge transfer can determine, by induction, disturbs on the
signal wiring and thus create malfunctions; this effect is particularly
critical in modern machines, with serial communications (canbus)
which are spread everywhere on the truck and which carry critical
informations.
B) in the worst case and when the amount of charge is very high, the
discharge process can determine failures in the electronic devices; the
type of failure can vary from an intermittently malfunction to a completely
failure of the electronic device.
IMPORTANT NOTE: it is always much easier and cheaper to avoid ESD from
being generated, than to increase the level of immunity of the electronic 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.
1) EMISSIONS. Three ways can be followed to reduce the emissions:
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5 OPERATIONAL FEATURES
-
Speed control.
Optimum behaviour an a slope due to the speed feedback:
- the motors 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
8.4).
Stable speed in every position of the accelerator.
Electronic differential feature with torque balance between external and
internal wheel.
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:
- the traction inverter sends a "hydraulic steering function" request to the
pump inverter on the can-bus line.
- moreover, if the pump inverter does not manage the steery function,
because it is managed by a motor other than the main hydraulic motor,
the traction inverter can manage an "hydraulic steering function" by
driving a hydro contactor which drive a hydraulic steering motor (output
C31).
Backing forward and reverse options are available, with the tune and the
speed of the function programmable with Zapi handset.
High efficiency of motor and battery due to high frequency commutations.
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.
Diagnostic function with Zapi handset for checking main parameters.
Built in BDI feature.
Flash memory, sw downloadable via serial link and via CANBUS.
Canopen interface available.
5.1 Diagnosis
The microcontrollers continually monitor the inverter and carry 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 drivers, can-bus
interface, if the switch sequence for operation is correct and if the output of
accelerator unit is correct, correct synchronization of the two CS, integrity of
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A1
CAN_H
A2
CANT_H
A3
CAN_POS
A4
CAN_L_OUT
A5
CANT_L
A6
CAN_L
A7
CAN_H_OUT
A8
CAN_NEG
B1
PCLRXD
B2
NCLRXD
B3
PCLTXD
B4
NCLTXD
B5
GND
B6
+12
B7
FLASH
B8
FLASH
C1
PENC_R
C2
NENC_R
C3
KEY
C4
CM
C5
SEAT
C6
FORWARD
C7
REVERSE
C8
ENABLE/BACK.
C9
PB
C10
C11
PENC_L
C12
NENC_L
C13
PHA_R
C14
PHB_R
C15
NPOTST
C16
PPOTST
C17
CPOTST
C18
CPOTB
C19
NPOTB
-BATT.
C20
NPOT
C21
CPOT
C22
PHA_L
C23
PHB_L
C24
NTHERM_R
C25
PTHERM_R
C26
NLC
C27
PLC
C28
NBRAKE
C29
PBRAKE
C30
PAUX
C31
NAUX
C32
-BATT
C33
PPOT
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NTHERM_L
C35
PTHERM_L
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A1
CAN_H
A2
CANT_H
A3
CAN_POS
A4
CAN_L_OUT
A5
CANT_L
A6
CAN_L
A7
CAN_H_OUT
A8
CAN_NEG
B1
PCLRXD
B2
NCLRXD
B3
PCLTXD
B4
NCLTXD
B5
GND
B6
+12
B7
FLASH
B8
FLASH
C1
PENC_R
C2
NENC_R
C3
KEY
C4
CM
C5
SEAT
C6
FORWARD
C7
REVERSE
C8
ENABLE/BACK.
C9
PB
C10
C11
PENC_L
C12
NENC_L
C13
PHA_R
C14
PHB_R
C15
NPOTST
C16
PPOTST
C17
CPOTST
C18
CPOTB
C19
NPOTB
-BATT.
C20
NPOT
C21
CPOT
C22
PHA_L
C23
PHB_L
C24
NTHERM_R
C25
PTHERM_R
C26
NLC
C27
PLC
C28
NBRAKE
C29
PBRAKE
C30
PAUX
C31
NAUX
C32
-BATT
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C33
PPOT
C34
NTHERM_L
C35
PTHERM_L
D1
-BATT
Negative output.
D2
2ND
D3
1ST
D4
ENABLE
D5
CMM
D6
5TH
D7
4TH
D8
3RD
D9
CPOTLIFT
D10
-BATT
D11
-BATT
D12
-BATT
D13
NPOTLIFT
D14
PPOTLIFT
Bridge 2-4 and 5-7 connect both built-in120 ohm can termination resistances.
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Bridge 2-4 connects one built-in 120 ohm can termination resistance, the second
will be connected in another module of the canbus net.
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-B
+BT
+BTF
Um; Vm; Wm
Us; Vs; Ws
-B
+BT
+BTF
Um; Vm; Wm
Us; Vs; Ws
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6.4.3 "Dualac2&hp"
View of the power bars:
Page - 34/89
-B
+BT
+BTF
Um; Vm; Wm
Us; Vs; Ws
-P
+P
+BPF
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-B
+BT
+BTF
Um; Vm; Wm
Us; Vs; Ws
-P
+P
+BPF
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7 DRAWINGS
7.1 Mechanical drawing
7.1.1 Dimensions of "Dualac2"
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8.3.1.b Slave
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8.3.2.b Slave
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8) SET TEMPERATURE
- DIGITAL: a digital (ON/OFF) motor thermal sensor is connected to C25
(C35) input.
- ANALOG: an analog motor thermal sensor is connected to C25 (C35)
(the curve can be customized on a customer request).
- NONE:
no motor thermal sensor switch is connected.
9) STEER TABLE
This parameter is used to set the correct steering table.
10) CNC#8 INPUT USE
- OPTION #1:
input C8 is used as enable input for the traction
request, active high (closed switch).
- OPTION #2:
input C8 activates backing function, active high (closed
switch).
- NONE:
input C8 isnt used.
11) SMART DISPLAY
- ON / OFF: if this option is programmed ON the communication with the
Smart display is active.
SUBMENU "ADJUSTMENTS"
1) SET POT BRK MIN
It 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 9.3). This procedure must be carried out only if the
"Pedal braking" option is programmed as "Analog".
2) SET POT BRK MAX
It records the maximum value of braking pedal potentiometer when the
braking pedal is fully pressed; the procedure is similar to the "Program Vacc"
function (see chapter 9.3). This procedure must be carried out only if the
"Pedal braking" option is programmed as "Analog".
3) SET BATTERY TYPE
It selects the nominal battery voltage.
4) ADJUST BATTERY
Fine adjustment of the battery voltage measured by the controller.
5) MAX STEER RIGHT
This is the function to record in the controller EEPROM the steering poti
output voltage when the wheels are fully turned right (maximum of the
steering poti range).
6) MAX STEER LEFT
This is the function to record in the controller EEPROM the steering poti
output voltage when the wheels are fully turned left (minimum of the steering
poti range).
7) SET STEER 0-POS.
This is the function to record in the controller EEPROM the steering poti
output voltage when the wheels are straight.
8) SET STEER RIGHT
This parameter sets the max steering angle in right direction.
9) SET STEER LEFT
This parameter sets the max steering angle in left direction.
10) THROTTLE 0 ZONE
It establishes a deadband in the accelerator input curve (see also curve
below).
11) THROTTLE X POINT
This parameter changes the characteristic of the accelerator input curve.
12) THROTTLE Y POINT
This parameter changes the characteristic of the accelerator input curve.
Page - 50/89
VACC MIN and VACC MAX are values programmable by the "Program
Vacc" function.
13) ADJUSTMENT#1 BDI
It adjusts the upper level of the battery discharge table.
14) ADJUSTMENT#2 BDI
It adjusts the lower level of the battery discharge table.
Page - 51/89
OPTION #3: Equal to OPTION#2 but the truck definitively stops after 380
hours.
ENTER).
5) AUX OUTPUT VOLTAGE
This parameter adjusts the voltage of the auxiliary output coil (hydraulic
steering contactor coil), PWM output C31.
6) THROTTLE 0 ZONE
It establishes a deadband in the lifting accelerator input curve (see also curve
below).
7) THROTTLE X POINT
This parameter changes the characteristic of the lifting accelerator input
curve.
8) THROTTLE Y POINT
This parameter changes the characteristic of the lifting accelerator input
curve.
Page - 53/89
% ' %
' ' '
CONFIG MENU
SET MODEL
% ' '
' ' '
CONFIG MENU
SET OPTIONS
' % '
' ' '
HOUR COUNTER
RUNNING
% ' '
% ' '
BATTERY CHECK
OFF
' ' %
' ' %
BATTERY CHECK
ON
' % '
' ' '
CONFIG MENU
SET OPTIONS
Page - 54/89
' % '
' ' '
Page - 55/89
Flow chart showing how to use the SET BATTERY TYPE adjustment.
DUALAC2 ZAPI V0.0
48V 350A 00000
% ' %
' ' '
CONFIG MENU
SET MODEL
% ' '
' ' '
CONFIG MENU
ADJUSTMENTS
' % '
' ' '
' ' %
' ' '
' % '
' ' '
Page - 56/89
% ' %
' ' '
CONFIG MENU
SET MODEL
% ' '
' ' '
CONFIG MENU
ADJUSTMENTS
' % '
' ' '
% ' '
% ' '
ADJUSTMENT BATTERY
82.1V
' ' %
' ' %
ADJUSTMENT BATTERY
84.5V
' ' '
' % '
' % '
' ' '
CONFIG MENU
ADJUSTMENTS
' ' '
' % '
Page - 57/89
Stop
Smooth
0.4
1.0
2.0
3.5
0.4, 1.0, 2.0, 3.5 are some possible values of the Acc. Smooth and Inv.
Smooth parameters (see the table below).
18) AUXILIARY TIME
It determines the time that the truck is hold on the ramp if the "stop on ramp"
option is ON.
Page - 59/89
The following table shows the different values at which the parameters can be
set.
PARAMETER
PROGRAMMED LEVEL
UNIT
0
Sec.
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Sec.
4.0
3.5
3.0
2.5
2.0
1.5
1.2
1.0
0.7
0.5
Sec.
8.9
8.3
7.7
7.1
6.6
6.0
5.5
4.9
4.4
3.8
Sec.
5.5
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
MAX SPEED FW
Hz
65
80
95
110
125
140
155
170
185
200
MAX SPEED BW
Hz
65
80
95
110
125
140
155
170
185
200
CUTBACK SPEED 1
10
20
30
40
50
60
70
80
90
100
CURVE CUTBACK
10
15
20
25
38
50
63
75
87
100
FREQUENCY CREEP
Hz
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3.0
%IMAX
47
53
59
65
70
76
82
88
94
100
BACKING SPEED
Hz
10
12
14
16
18
BACKING TIME
Sec.
0.3
1.1
1.9
2.8
3.7
4.5
5.4
6.3
7.1
8.0
ACC. SMOOTH
1.0
1.2
1.5
1.7
2.0
2.2
2.5
2.7
3.0
3.5
INV. SMOOTH
0.4
0.6
0.8
1.0
1.2
1.5
1.7
2.0
2.5
3.0
MAXIMUM CURRENT
STOP SMOOTH
Hz
10
12
15
17
20
22
25
27
AUXILIARY TIME
Sec.
0.2
0.4
0.8
1.5
(*)
(**)
The acceleration time shown is the time from 0 Hz to 100 Hz. This is the
ideal ramp calculated by the software; the real ramp could change as a
function of motor control parameter setting and, obviously, as a function
of the load.
The braking feature is based upon deceleration ramps. The value shown
in the table is the time to decrease the speed from 100 Hz to 0 Hz. This
is the ideal ramps calculated by the software; the real ramp could
change as a function of motor control parameter setting and, obviously,
as a function of the load.
Page - 61/89
15)
16)
17)
18)
19)
Page - 62/89
when the 4th speed request is active. The value of DV applied to the motor is
a function of the motor current. Aim of this function is to reduce, as for as
possible, the speed change when the motor is loaded. Increasing the
parameter, the DV is increased.
5TH SPEED FINE
This parameter sets the voltage compensation (DV) applied to the motor
when the 5th speed request is active. The value of DV applied to the motor is
a function of the motor current. Aim of this function is to reduce, as for as
possible, the speed change when the motor is loaded. Increasing the
parameter, the DV is increased.
5TH SPEED COMP.
This parameter sets the voltage compensation (DV) applied to the motor
when the 5th speed request is active. The value of DV applied to the motor is
a function of the motor current. Aim of this function is to reduce, as for as
possible, the speed change when the motor is loaded. Increasing the
parameter, the DV is increased.
HYDRO SPEED FINE
This parameter sets the pump motor speed (voltage applied to the motor)
when the hydraulic steering function request is active.
HYDRO COMPENS.
This parameter sets the voltage compensation (DV) applied to the motor
when the hydro speed request is active. The value of DV applied to the motor
is a function of the motor current. Aim of this function is to reduce, as for as
possible, the speed change when the motor is loaded. Increasing the
parameter, the DV is increased.
HYDRO TIME
Hydraulic steering function delay.
PROGRAMMED LEVEL
UNIT
0
SPEED LIMIT
0 - 100
PUMP IMAX
%IMAX
50
55
61
66
72
77
83
88
94
100
Sec.
0.2
0.4
0.6
0.8
1.5
2.5
3.5
Sec.
0.2
0.4
0.6
0.8
1.5
2.5
3.5
CREEP SPEED
0 - 100
COMPENSATION
0 - 100
0 - 100
0 - 100
0 - 100
0 - 100
0 - 100
0 - 100
0 - 100
0 - 100
0 - 100
0 - 100
0 - 100
HYDRO COMPENS.
0 - 100
Sec.
0 25.5
HYDRO TIME
(*)
(**)
Page - 63/89
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
' % '
' ' '
ACCELER. DELAY
LEVEL = 4
% ' '
% ' '
RELEASE BRAKING
LEVEL = 5
' ' %
' ' %
RELEASE BRAKING
LEVEL = 6
Page - 64/89
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
Page - 65/89
9) Set the FREQUENCY CREEP level starting from level 0.3 Hz. The machine
should just move when the accelerator microswitch is closed. Increase the
Level accordingly.
10) Set the Speed Reductions as required. Make adjustments to CUTBACK
SPEED 1 Check the performance with the accelerator pedal totally
depressed. If the machine is a forklift, check the performance with and
without load.
11) RELEASE BRAKING. Operate the machine at full speed. Release the
accelerator pedal. Adjust the level to your requirements. If the machine is a
forklift, check the performance with and without load.
12) INVERSION BRAKING. Operate the machine at 25% full speed. Whilst
travelling INVERT the Direction Switch. Set a soft Level of Inversion Braking.
When satisfactory, operate the machine at Full Speed and repeat. If the
machine is a Forklift, repeat the tests and make adjustments with and without
load. The unladen full speed condition should be the most representative
condition.
13) PEDAL BRAKING (If used). Operate the machine at full Speed. Release the
accelerator pedal and press the Pedal Brake. Set braking level to your
requirements.
14) Set MAX SPEED FORW.
15) Set MAX SPEED BACK (Reverse).
16) Set BACKING SPEED and BACKING TIME if these options are used.
17) Make the choice for the truck behaviour on a slope (see chapter 8.4). If the
"Stop on ramp" option is ON, set the desired value of "auxiliary time"
parameter.
18) Set SET TEMPERATURE, setting the motor thermal sensor type used.
19) Set MAIN CONT VOLTAGE, setting the main contactor coil voltage.
20) Set AUX OUTPUT VOLTAGE (if used), setting the auxiliary output voltage.
Page - 67/89
Page - 69/89
7) VOLTAGE BOOSTER
This is the booster of the voltage supplied to the motor in load condition; it is
expressed in a percentage of the full voltage.
8) BATTERY VOLTAGE
Level of battery voltage measured at the input of the key switch.
9) SEAT SWITCH
The level of the Seat Microswitch digital input.
- ON / +VB = input active, switch closed.
- OFF / GND = input non active, switch opened.
10) FORWARD SWITCH
The level of the Forward direction digital input FW.
- ON / +VB = input active, switch closed.
- OFF / GND = input non active, switch opened.
11) BACKWARD SWITCH
The level of the Reverse direction digital input BW.
- ON / +VB = input active, switch closed.
- OFF / GND = input non active, switch opened.
12) ENABLE SWITCH
The level of the Enable digital input:
- ON / +VB = input active, switch closed.
- OFF / GND = input non active, switch open.
Page - 71/89
Flow Chart showing how to use the TESTER function of the Digital Console.
DUALAC2 ZAPI V0.0
48V 350A 00000
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
% ' '
% ' '
MAIN MENU
TESTER
' % '
' ' '
MOTOR VOLTAGE
%
% ' '
% ' '
Remember it is not possible to make any changes using TESTER. All you
can do is measure as if you were using a pre-connected multimeter.
Page - 72/89
9 OTHER FUNCTIONS
9.1 Save and Restore function
SAVE function allows to transfer controller parameters to the Pc console
memory. With this function, a copy of the controller set of parameters can be
retained in a Pc and downloaded to another controller (see RESTORE).
RESTORE function allows to download controller parameters from the Pc
console memory to the controller Eeprom. Thus a copy of the parameters
stored in a Pc can be downloaded in a controller avoiding the parameter
setting operation.
For more details, please refer to Pc console manual.
CODE
00005 #02 20C
% ' '
% ' '
CODE
Page - 73/89
CLEAR LOGBOOK?
YES=ENTER NO=OUT
' % '
' ' '
' % '
' ' '
MAIN MENU
PARAMETER CHANGE
% ' '
% ' '
MAIN MENU
PROGRAM VACC
' % '
' ' '
VACC SETTING
4.8
4.8
Page - 74/89
' % '
' ' '
MIN
0.0
VACC
-
MAX
0.0
MIN
0.6
VACC
MAX
4.4
Page - 75/89
ALARM
STRING
Ma
ster
CONTROLLER
STATUS
Slave
Init
Stby
Motor
running
X
WATCHDOG
17
LOGIC
FAILURE #3
18
LOGIC
FAILURE #2
19
LOGIC
FAILURE #1
30
VMN LOW
Page - 76/89
DESCRIPTION
Alarm: the
Watchdog circuit
has been
triggered
Alarm: failure in
over-load
protection hw
circuit
Alarm: failure in
U, V, W voltage
feedback circuit
Alarm: an
overvoltage or
undervolt.
condition has
been detected
Alarm: wrong
voltage on motor
power outputs;
failure in the
power section or
in the mosfet
driver circuit or in
the motor
Co
de
ALARM
STRING
Ma
ster
Slave
CONTROLLER
STATUS
Init
Stby
DESCRIPTION
Motor
running
31
VMN HIGH
Alarm: wrong
voltage on motor
power outputs;
failure in the
power section or
in the mosfet
driver circuit or in
the motor
53
STBY I HIGH
Alarm: wrong
voltage in the
current sensor
feedback circuit
60
CAP
CHARGE
74
DRIVER
SHORTED
75
CONTACTOR
DRIVER
Alarm: power
capacitor voltage
does not increase
when the key is
turned ON; failure
in the power
section, or in the
Logic PCB, or in
the driver PCB, or
in the motor
Alarm: line
contactor coil
driver is shorted
Alarm: line
contactor coil
driver is open (not
able to drive the
coil to the correct
voltage)
Page - 77/89
Co
de
ALARM
STRING
Ma
ster
CONTROLLER
STATUS
Slave
Init
Stby
X
Motor
running
X
DESCRIPTION
Alarm:
-Init: the LC and
EB coil driver
protection circuit
is damaged
- Stby or running:
short on LC coil
or EB coil
76
COIL
SHORTED
37
CONTACTOR
CLOSED
Alarm: line
contactor power
contact is stuck
38
CONTACTOR
OPEN
Alarm: line
contactor power
contact does not
pull-in
82
ENCODER
ERROR
84
STEER
SENSOR KO
86
PEDAL WIRE
KO
245
WRONG SET
BATTERY
246
SLAVE KO
Page - 78/89
Alarm: motor
speed sensor
(encoder) does
not work properly
Alarm: steering
poti signal out of
range
Alarm: fault in
accelerator
negative (NPOT)
input circuit
Alarm: the battery
voltage does not
correspond to
SET BATTERY
programming
Alarm: Master C
detects a Slave
C malfunctioning
To remove alarm
cause
To remove alarm
cause and activate a
traction request
To remove alarm
cause
Co
de
ALARM
STRING
Ma
ster
CONTROLLER
STATUS
Slave
Init
Stby
246
MASTER KO
Motor
running
X
250
INPUT
MISMATCH
253
AUX OUTPUT
KO
13
EEPROM KO
61
HIGH
TEMPERATURE
65
MOTOR
TEMPERATURE
66
BATTERY
LOW
DESCRIPTION
Alarm: Slave C
detects a Master
C malfunctioning
or a mismatch
between inputs
status and Master
commands (via
Canbus)
Alarm: Slave C
has detected a
mismatch
between inputs
status and the
input status
transmitted via
Canbus by
Master C
Alarm: EB coil
driver shorted or
open
Warning: Eeprom
fault, controller
will use default
parameters
Warning: Master
or Slave or both
temperature
higher than 75C
Warning: Master
or Slave or both
motors
temperature high
Warning: battery
charge level
below 20%
To remove Warning
cause
To remove Warning
cause
To remove Warning
cause
Page - 79/89
Co
de
ALARM
STRING
Ma
ster
CONTROLLER
STATUS
Slave
Init
Stby
VACC NOT
OK
79
INCORRECT
START
80
FORWARD +
BACKWARD
249
THERMIC
SENSOR KO
251
WAITING
FOR NODE#4
251
WAITING
FOR NODE#3
247
NO CAN
MESSAGE #4
247
NO CAN
MESSAGE #3
244
SLAVE
WARNING
HANDBRAKE
250
Page - 80/89
X
X
Motor
running
78
DESCRIPTION
Warning:
accelerator signal
(CPOT) voltage
higher than
VACC MIN +1V
while the traction
enable switch is
open
Warning: wrong
traction request
sequence
Warning: forward
and reverse
inputs are both
active
Warning: Master
or slave
temperature
sensor is out of
range
Warning: Master
C signals that
Slave C is in
alarm status
Warning: Slave
C signals that
Master C is in
alarm status
Alarm: Master
has lost Can
communication
with the Slave
Alarm: Slave has
lost Can
communication
with the Master
Warning: Slave
C has a warning
Warning: the
operator try to
travel with the
handbrake active
To remove Warning
cause
To remove Warning
cause
To remove Warning
cause
To remove Warning
cause
To remove Warning
cause
To remove Warning
cause
To remove Warning
cause
To remove alarm
cause
To remove Warning
cause
To remove Warning
cause
Co
de
ALARM
STRING
Ma
ster
CONTROLLER
STATUS
Slave
Init
241
DATA
ACQUISITION
248
CHECK UP
NEEDED
Stby
X
DESCRIPTION
Warning:
Maximum current
adjustment
procedure is in
progress (NOTE:
this
procedure has to
be done only by
Zapi test
department)
Warning:
maintenance time
is reached
To remove Warning
cause and to activate
traction request
Motor
running
To remove Warning
cause
Page - 81/89
7) CAPACITOR CHARGE
Follows the charging capacitor system:
When the key is switched ON, the inverter tries to charge the capacitor
through a power resistance, and check if the capacitor are charged within a
timeout. If they do not charge, an alarm is signalled; the main contactor is not
closed.
Possible reasons:
A) the charging resistance is opened.
B) The charging circuit has a failure.
C) There is a problem in the power section.
8) MAIN CONTACTOR ALARMS
COIL SHORTED:
When the key is switched ON the Controller checks the LC coil driver
shortcircuit protection hardware. If it does not react in a correct way to the C
stimulus, the alarm is signalled. Replace the logic board. When the fault
occurs while the LC is closed, the alarm signals a shortcircuit across LC coil.
Check if there are external shortcircuit and if the ohmic value of the MC coil is
correct; otherwise replace the logic.
DRIVER SHORTED:
When the key is switched ON, the C checks that the LC coil driver is not
shorted; if it is, this alarm is signalled. Preliminary, check if there is an
external short or low impedance pull-down between NLC (C26) and -BATT. If
no external causes can be found out, replace the controller.
CONTACTOR DRIVER:
When the initial diagnosis is finished, the traction logic closes the LC and
checks the voltage on the Drain of the driver. If this is not low , the driver is
not able to close an alarm is signalled. Replace the logic.
CONTACTOR OPEN:
The main contactor coil has been driven by the logic board, but the contactor
does not close. Two possible reasons:
A) the wires to the coil are interrupted or not well connected.
B) the contact of the contactor is not properly working (does not pull-in).
CONTACTOR CLOSED:
Before driving the LC coil, the controller checks if the LC contact is stuck.
The controller drives the bridge for a while, trying to discharge the capacitor
bank. If they don't discharge, the fault condition is entered. It is suggested to
check the contactor contact, if it is mechanically stuck.
9) ENCODER ERROR
This alarm is signalled in following condition: the frequency supplied to the
motor is higher than 20 Hz, and the signal feedback from the encoder has a
jump higher than 20 Hz in few tens millisecond. This condition clearly shows
a malfunctioning of the encoder signal. It is suggested to preliminary check
the encoder wiring; if no fault is found in the wiring it is necessary to replace
the encoder.
10) STEER SENSOR KO
This is an alarm which signals an out of range of the steering potentiometer
signal. The fault condition is entered in these two following conditions:
Page - 82/89
11)
12)
13)
14)
15)
16)
17)
18)
Page - 83/89
Page - 84/89
ALARM
STRING
Ma
ster
CONTROLLER
STATUS
Slave
Init
Stby
28
PUMP VMN
LOW
56
PUMP STBY I
HIGH
242
Sla
ve
PUMP
TEMPERAT.
Motor
running
X
DESCRIPTION
Alarm: wrong
voltage output of
pump chopper;
the motor voltage
feedback is not
coherent with
applied PWM
Alarm: in stby
condition (no
PWM applied to
pump chopper),
the pump current
sensor feedback
is out of the zero
current window
Warning: the
pump chopper
temperature is
higher than 75C
Page - 85/89
Cod
e
ALARM
STRING
Ma
ster
CONTROLLER
STATUS
Slave
Init
Stby
242
Ma
ster
PUMP
WARNING
243
PUMP INC.
START
244
PUMP VACC
NOT OK
245
PUMP TH.
SENS. KO
Motor
running
X
DESCRIPTION
Warning: Master
controller signals
that Slave C has
detected a fault in
the pump
chopper
Warning: pump
chopper incorrect
start sequence
Warning: pump
chopper
accelerator
voltage is 1V
greater than the
minimum value
programmed
Warning: pump
chopper
temperature
sensor is out of
range
To remove warning
cause
To remove warning
cause
To remove warning
cause
To remove Warning
cause
Page - 86/89
Page - 87/89
Description
C16507
C16505
C16520
C29523
SW 180 80 V
Single Pole Contactor
C29522
SW 180 48 V
Single Pole Contactor
C29508
SW 180 24 V
Single Pole Contactor
Page - 88/89
C12529
C12532
C12530
C12796
12 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 Foot pedal or Tiller microswitch. Using a suitable test meter, confirm
that there is no electrical resistance between the contacts by measuring the volt
drop between the terminals. Switches should operate with a firm click sound.
Microswitches should be checked every 3 months.
Check the Battery cables, cables to the inverter, and cables to the motor. Ensure
the insulation is sound and the connections are tight.
Cables should be checked every 3 months.
Check the mechanical operation of the pedal or tiller. Are the return springs ok.
Do the potentiometers wind up to their full or programmed level.
Check every 3 months.
Check the mechanical operation of the Contactor(s). Moving contacts should be
free to move without restriction.
Check every 3 months.
Checks should be carried out by qualified personnel and any replacement 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 requirements should
be made after consulting a Zapi Agent. The supplier is not responsible for any
problem that arises from wiring methods that differ from information included in
this Manual.
During periodic checks, if a technician finds any situation that could cause
damage or compromise safety, the matter should be bought to the attention of a
Zapi Agent immediately. The Agent will then take the decision regarding
operational safety of the machine.
Remember that Battery Powered Machines feel no pain.
NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER.
Page - 89/89