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COMBIAC2 - Zapi Inc USA

1. 4BT BTF Um Vm Wm Us Vs Ws Negative of the battery Positive of the battery if the power fuse is not present the positive cable coming from LC contact must be connected to this power connection Positive of battery before power fuse must be connected to positive cable coming from LC contact Connection bars of the three traction motor phases follow this sequence and the indication on the motor Connection bars of the three pump motor phases follow this sequence and the indication on the motor AFOZPOBA COMBIAC2 User Manual 6 3 2 COMBIAC2 Power View of the power bars D e Ii Z e ES E B Negative of the battery BT Positive of the battery if the power fuse is not present the positive cable coming from LC contact must be connected to this power connection BTF Positive of battery before power fuse must be connected to positive cable coming from LC contact Um Vm Wm Connection bars of the three traction motor phases follow this sequence and the indication on the motor Us Vs Ws Connection bars of the three pump motor phases follow this sequence and the indication on the motor AFOZPOBA COMBIAC2 User Manual Page 27 65 7 DRAWINGS 7 1 Mechanical drawing 7 1 1 Dimensions of COMBIAC2 asi HAMOd TVOJO ke 7 BD 9 001
2. AA 5 SPECIFICATION 6 21 Technical specifications DOMBIAC 2 iine etas en lek us ciini tb na ssim ad Re ns aec 6 22 Block diagram COMBIAUD itenim Eat tena Leva a hee neja ne rra pe n ade 6 2 3 Technical specifications UCOMBIAC2 Power 7 2 4 Block diagram COMBIAC2 Power 7 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 8 3 1 Microswitches M TED 8 32 Analog UMi c TA 8 3 3 Other analog control unit zeva prei neenaka na aka nennen nenen 9 DEMEMEI TSCA con HE 10 4 INSTALLATION HINTS iiiiiixtssiu u tan LR RRe kad bena aka Ht S REA MAR kana 11 4 1 Material OVervieW RR IU TM 11 4 1 1 Connection GANOS ER 11 41 2 eer rm 11 LCS AEN rrr 11 4 2 Installation of the hardware rne kink kk hk xke 11 4 2 1 Positioning and cooling of the controller 12 422 Wirings power CADISS c 12 4 2 3 Wirings CAN connections and possible interferences 12 424 Wirings TO COINS GONI aii rei elana a aaa kre eap Etre tutes 15 42 5 Encoder installation siva ani fini genera re ea etna a te eri Mr a venait Eden 15 4 2 6 Main contactor and key connection eeeeeeseeeeeee 16 42 7 Insulation of truck Iram uei aa re et metere urit uae se f
3. Using the CONFIG MENU of the programming console the user can configure the following functions SUBMENU SET OPTIONS 1 HOUR COUNTER RUNNING the counter registers travel time only KEYON the counter registers when the key switch is closed 2 BATTERY CHECK ON the battery discharge level check is carried out when the battery level reaches 10 an alarm is signalled and the maximum current is reduced to the half of the programmed value OFF the battery discharge level check is carried out but no alarm is signalled 3 TRACTION CUTOUT ON OFF when the Battery low alarm appears if this option is programmed ON the traction speed is reduced to 60 Hz 4 LIFT CUTOUT ON OFF when the Battery low alarm appears if this option is programmed ON the pump speed is reduced to Cutback speed value see chapter 8 5 2 5 HYDRO KEY ON ON OFF ifthis option is programmed ON the traction inverter manages an hydraulic steering function when the key is switched ON 6 STOP ON RAMP ON the stop on ramp feature truck electrically hold on a ramp is managed for a time established by auxiliary time parameter OFF the stop on ramp feature is not performed 7 PEDAL BRAKING ANALOG the mechanical brake pedal has a switch and a potentiometer installed When the accelerator is released and the pedal brake is pushed the inverter performs an electrical braking whose intensity is proportional to the brake pedal
4. Procedure is detailed on Chapter 9 3 5 Set the MAXIMUM CURRENT Current using the table on Chapter 8 5 2 6 Setthe Acceleration and Deceleration Delay requirements for the pump 7 Setthe MIN SPEED LIFT level starting from 12 0 Hz The pump should just turn when the request microswitch is closed Increase the level accordingly 8 Set the Speed Reductions as required Make adjustments to CUTBACK SPEED Check the performance with the full request Check the performance with and without load AFOZPOBA COMBIAC2 User Manual Page 47 65 9 Set MAX SPEED LIFT max speed of pump motor 10 Set HYD SPEED FINE to adjust the hydraulic steering speed pump motor speed when HYDRO function is requested 11 Set AUXILIARY TIME time delay before pump stops when an hydraulic steering function request is switched off 12 Set SET TEMPERATURE setting the motor thermal sensor type used 13 Set AUX OUTPUT VOLTAGE if used setting the auxiliary output voltage 8 9 Tester description of the COMBIAC2 and COMBIAC2 Power function The most important input or output signals can be measured in real time using the TESTER function of the console The Console acts as a multimeter able to read voltage current and temperature In the following chapter a list of relative measurements for different configurations 8 9 1 Traction Page 48 65 1 MOTOR VOLTAGE This is the voltage supplied to the motor by the inver
5. oo Page 39 65 Flow chart showing how to use the SET BATTERY TYPE adjustment COMBIAG2 ZAPI VO O 48V 350A 00000 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG NOM Menu nn 3 The Display will show SET MODEL CONFIG MENU SET MODEL 4 Press ROLL UP button until mug ADJUSTMENTS Menu appears uu CONFIG MENU ADJUSTMENT 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Dm Menu nna 7 The display will show SET BATTERY TYPE accessi EE 80V 8 Press SET UP to choose nominal value of the Dum battery ooo SET BATTERY TYPE 9 New battery value appears p 10 Press OUT ARE YOU SURE 11 Confirmation request appears NEGO EMI OLI 12 Press ENTER to accept the changes or press OUT if you do not accept the changes 13 Press OUT Display now shows the Opening ooo Zapi Menu Dm Page 40 65 AFOZPOBA COMBIAC2 User Manual Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG Menu 3 The Display will show SET MODEL 4 Press ROLL UP button until ADJUSTMENT Menu appears 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 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 Pre
6. 03 18 C 9 If an Alarm has not occurred the Display will show ALARM NULL AFOZPOBA COMBIAC2 User Manual 10 When you have finished looking at the Alarms press OUT to exit the ALARMS menu 11 The Display will ask CLEAR LOGBOOK sies le inni piedad YES ENTER NO OUT 12 Press ENTER for yes or OUT for NO 13 Press OUT to return to the Opening Zapi Display 9 3 Description of Console Program Vacc function This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal It enables compensation for non symmetry of the mechanical system between directions The operation is performed by operating the pedal after entering the PROGRAM VACC function Flow Chart showing how to use the PROGRAM VACC function of the Digital Console COMBIAG2 ZAPI VO O 48V 350A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General Menu s m O MAIN MENU PARAMETER CHANGE 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display Bod Bod 5 The Display will show 6 Press ENTER to go into the PROGRAM VACC routine 7 The Display will show the minimum and Y VACC SETTING maximum values of potentiometer wiper output 4 8 Both directions can be shown ge 8 Press ENTER to clear these values Omo Display will show 0 0 000 9 Select Forward Direction close any
7. 30 mA range The CPOTBRK C18 signal range is from 0 to 5 V or from 0 V to 10 V 2 Connections C25 PTHERMR and C24 NTHERMR are used for the traction motor thermal sensor Connections C35 PTHERML and C34 NTHERML are used for the pump motor thermal sensor Sensors can be digital on off sensor normally closed or analog See also chapter 8 4 for more explanation 3 Input C17 is an analog input whose typical application is for lifting It should be in a 3 wire configuration 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 The CPOTLIFT C17 signal range is from 0 to 5 V or from 0 V to 10 V AFOZPOBA COMBIAC2 User Manual Page 9 65 3 4 Speed feedback The traction motors 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 45 Vor 12 V electric output open collector NPN or PNP push pull For more details about encoder installation see also chapter 4 2 5 Page 10 65 AFOZPOBA COMBIAC2 User Manual 4 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colours they mean E These are informations useful for anyone is working on the installation or a deeper examination of the content A These are Warning boxes they describe operations that can lead
8. 4 1 3 Confirm correct installation of all wires Use the Console s TESTER function to assist 4 Perform the accelerator signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on Chapter 9 3 5 Perform the steering potentiometer signal acquisition using the parameters in Adjustment menu see Chapter 8 4 1 Remember turning the wheel to right direction voltage has to increase AFOZPOBA COMBIAC2 User Manual 6 Set the maximum steering angles right and left direction use the parameters in Adjustment menu see Chapter 8 4 1 7 Setthe MAXIMUM CURRENT Current using the table on Chapter 8 5 1 8 Set the Acceleration Delay requirements for the machine Test the parameter setting in both directions 9 Set the FREQUENCY CREEP level starting from level 0 6 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 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 traveling INVERT the Direction Switch Set a s
9. ON OFF ET POT BRK MIN ET POT BRK MAX ET BATTERY TYPE DJUST BATTERY HROTTLE O ZONE THROTTLE X POINT THROTTLE Y POINT ADJUSTMENT 02 ADJUSTMENT 01 AIN CONT VOLT AUX OUTPUT VOLT 2 0 uU BDI BDI en m 24 36 48 72 80 96 iM 1 1 X X ib d 31 38 MN AFOZPOBA COMBIAC2 User Manual 8 3 2 Pump configuration HEADING MAIN MENU L__ jum ACCELERATION DELAY 0 9 SET MODEL DECELERATION DELAY 0 9 MAX SPEED LIFT iz MIN SPEED LIFT Hz HYD SPEED FINE Hz CUTBACK SPEED x SET OPTIONS SET TEMPERATURE ANALOG DIGITAL NONE MAXIMUM CURRENT 0 9 AUXILIARY TIME Sec TESTER OTOR VOLTAGE REQUENCY z ADJUSTMENTS THROTTLE O ZONE CODER z THROTTLE X POINT SLIP VALU iz THROTTLE Y POINT Z CURRENT RMS A AUX OUTPUT VOLT a TEMPERATURE C OTOR TEMPERAT C VOLTAGE BOOSTER Z f L V SEAT SWITCH ON OFI FORW SWITCH ON OFF BACK SWITCH ON OFF ENABLE SWITCH ON OFF FTING SWITCH ON OFI HYDRO SPEED REQ ON OFF LIFTING CONTROL V SAVE PARAMETER RESTORE PARAMETER ALARMS RAR k M VACC SETTING MIN MAX NOT MOTOR DATA AVAILABLE AFOZPOBA COMBIAC2 User Manual Page 33 65 8 4 COMBIAC2 and COMBIAC2 Power function configuration 8 4 1 Traction Page 34 65
10. X X Alarm failure in To remove alarm FAILURE 2 U V W voltage condition activation feedback circuit of traction request 19 LOGIC X X X X X Alarm an To recycle the key FAILURE 1 overvoltage or switch undervolt condition has been detected 30 VMN LOW X X X X X Alarm wrong If the alarm is present voltage on motor in Init status remove power outputs the alarm condition failure in the If the alarm has power section or occurred in stby or in the mosfet running mode it is driver circuit or in necessary to remove the motor alarm condition and to activate a traction request Page 55 65 Co ALARM Tra Pump CONTROLLER DESCRIPTION Condition that has to de STRING ctio STATUS occur to come out n from alarm status Init Stby Motor running 31 VMN HIGH X X X X Alarm wrong If the alarm is present voltage on motor in Init status remove power outputs the alarm condition failure in the If the alarm has power section or occurred in stby or in the mosfet running mode it is driver circuit or in necessary to remove the motor alarm condition and to activate a traction request 53 STBYIHIGH X X X X Alarm wrong If the alarm is present voltage in the in Init status remove current sensor the alarm condition feedback circuit If the alarm has occurred in stby or running mode it is necessary to remove alarm condition and to activate a traction request 60 CAP X X X Alarm power To remov
11. console n 59 RECOMMENDED SPARE PARTS FOR INVERTER nana nnne 63 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED 64 APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN GRAPHIC AND LAYOUT CP PROJECT MANAGER FG TECHNICAL ELECTRONIC PP MANAGER VISA SALES MANAGER VISA PN Publication N AFOZPOBA Edition June 2006 Page 4 65 AFOZPOBA COMBIAC2 User Manual 1 INTRODUCTION Within the ZAPIMOS family the COMBIAC2 inverter is the model suitable for control of pairs of 3 0 kW to 7 0 kW motors with pump and traction motor functions These controllers have been expressly designed for battery powered applications traction and hydraulic functions They are fit for electric trucks AFOZPOBA COMBIAC2 User Manual Page 5 65 2 SPECIFICATION 2 1 Technical specifications COMBIAC2 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 Ug d aaa 24 36 48 72 80 V Maximum current 24 V ssssssssss 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 ITEGUBNOV
12. contactor power cause within a contact does not timeout if the timeout pull in is elapsed it is necessary to re cycle the key 82 ENCODER X X X Alarm motor To recycle the key ERROR speed sensor encoder does not work properly 86 PEDAL WIRE X X X X Alarm fault in To remove alarm KO accelerator cause and activate a negative NPOT traction request input circuit 245 WRONG SET X X Alarm the battery To remove alarm BATTERY voltage does not cause correspond to SET BATTERY programmation 246 PUMP KO X X X X Alarm Traction To recycle the key UC detects a Pump uC malfunctioning AFOZPOBA COMBIAC2 User Manual Page 57 65 Co ALARM Tra Pump CONTROLLER DESCRIPTION Condition that has to de STRING ctio STATUS occur to come out n from alarm status Init Stby Motor running 246 MASTER KO X X X X Alarm Pump C To recycle the key detects a Traction UC malfunctioning or a mismatch between inputs status and Traction commands via Canbus 250 INPUT X X X X Alarm Pump uC To recycle the key MISMATCH has detected a mismatch between inputs status and the input status transmitted via Canbus by Traction uC 253 AUXOUTPUT X X X X Alarm EB coil If the alarm is present KO driver shorted or in Init status remove open the alarm cause If the alarm has occured in stby or running mode it is necessary to remove alarm cause and to act
13. g TD H SE E Hil pN sis c ell pe E Hi o i S A K ll l I bod ON VU uet i ri REM ji z LI eu n LEE 8 ESI ES la CFG Pee Sor imm A a gt B C C OPTIONAL POWER FUSE MB BOLI 9o O lem SSR AB VUM VVM VWN VUS VVS VWs AA Af 10 X MB MALE SCREW aj Ge So sej em tj i A o pooo l EL l he a Lu U CONNECTOR CONSOLE MOLEX ma AMPSEAL Plug P N 776164 1 P N 09 50 1081 AMPSEAL Plug P N 776286 1 AFOZPOBA COMBIAC2 User Manual Page 28 65 GShd N3MOd TvNOILAD 9 621 O Page 29 65 7 1 2 Dimensions of COMBIAC2 Power 9 001 Ove oz Z ESL Kik EL g SAU AG n vas NS p a O CH OPTIONAL POWER FUSE M8 BOLD f C BA VUM VVM VWM VUS VVS VWS ER EN Zam h S xl es V Ji W JJ KA J KU jj AN q 10 X MB MALE SCREW Du f Ce leg he a SEEN Tfi m EE J s WO eil yY A fA H v ANS
14. if the Pedal braking option is programmed as Analog 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 SET BATTERY TYPE It selects the nominal battery voltage ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller THROTTLE 0 ZONE It establishes a deadband in the accelerator input curve see also curve below THROTTLE X POINT These parameter change the characteristic of the accelerator input curve THROTTLE Y POINT These parameter change the characteristic of the accelerator input curve VACC MIN and VACC MAX are values programmable by the Program Vacc function ADJUSTMENT 401 BDI It adjusts the upper level of the battery discharge table ADJUSTMENT 02 BDI It adjusts the lower level of the battery discharge table AFOZPOBA COMBIAC2 User Manual Page 35 65 10 MAIN CONT VOLTAGE This parameters adjusts the Line contactor coil voltage PWM output C26 11 AUX OUTPUT VOLTAGE This parameters adjusts the Electric brake coil voltage PWM output C28 8 4 2 Pump Using the config menu of the programming console the user can configure the following functions SUBMENU SET OPTIONS 1 SET TEMPERATURE DIGITAL a digital ON OFF motor thermal s
15. interlock MIN VACC MAX switches that may be in the system a a O O AFOZPOBA COMBIAC2 User Manual Page 53 65 10 Slowly depress the accelerator pedal or tiller butterfly to its maximum value The new minimum and maximum voltages will be displayed on the Console plus an arrow indicating the direction CG MAX 4 4 11 Select the Reverse Direction and repeat Item MIN VA 10 0 6 T C 12 When finished press OUT ARE YOU SURE YES ENTER NO OUT 14 Press ENTER for yes or OUT for NO MAIN MENU PROGRAM VAGG 13 The Display will ask ARE YOU SURE 15 When finished the Console shows 16 Press OUT again to return to the Opening Zapi ooo Menu nma Page 54 65 AFOZPOBA COMBIAC2 User Manual 10 COMBIAC2 INVERTER DIAGNOSTIC 10 1 Fault codes AFOZPOBA COMBIAC2 User Manual Co ALARM Tra Pump CONTROLLER DESCRIPTION Condition that has to de STRING ctio STATUS occur to come out n from alarm status Init Stby Motor running 8 WATCHDOG X X X X X Alarm the If the alarm is present Watchdog circuit in Init status remove has been the alarm condition triggered If the alarm has occurred in stby or running mode it is necessary to remove alarm condition and to activate a traction request 17 LOGIC X X X Alarm failure in To remove alarm FAILURE 3 over load condition activation protection hw of traction request circuit 18 LOGIC X
16. 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 4096 more than the battery nominal voltage or if the key is switched off before the battery power line is disconnected 4 2 7 Insulation of truck frame A As stated by EN 1175 Safety of machinery Industrial truck chapter 5 7 there shall be no electrical connection to the truck frame So the truck frame has to be isolated from any electrical potential of the truck power line 4 3 Protection and safety features oe Ra 4 3 1 Protection features Page 16 65 Battery polarity inversion It is necessary to fit a MAIN CONTACTOR to protect the inverter against reverse battery polarity and for safety reasons Connection Errors All inputs are protected against connection errors Thermal protection If the controller temperature exceeds 75 C the maximum current is reduced in proportion to the thermal increase The temperature can never exceed 100 C AFOZPOBA COMBIAC2 User Manual 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 belo
17. steering function request is switched off The following table shows the different values at which the parameters can be set PROGRAMMED LEVEL PARAMETER UNIT 1 2 s a4 s se 7 s ACCELERATION DELAY Sec 1 0 1 2 1 4 16 1 8 20 25 53 4 5 60 MAX SPEED LIFT Hz 6 200 HYD SPEED FINE Hz 0 50 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 44 65 AFOZPOBA COMBIAC2 User Manual After changing a parameter press ENTER to confirm data when requested by the message on the console Parameters modified and optimized on one unit can be stored by the Zapi Pc console SAVE and then downloaded RESTORE to another controller thus allowing fast and standardized settings see Pc console manual for details Flow Chart showing how to make Parameter changes using Digital Console fitted with Eprom CK ULTRA 1 Opening Zapi Display Ea ZAPI VO 0 48V 350A 00000 go 2 Press ENTER to go into the General Menu
18. 16 LIFTING CONTROL From 0 0 to 5 0 V The voltage on the wiper of the lift potentiometer CPOTLIFT on CNC 17 is halved inside the controller and then recorded on this reading That means the actual wiper voltage is in the range 0 to 10 V meanwhile the corresponding potentiometer reading is in the range 0 0 to 5 0 Vdc AFOZPOBA COMBIAC2 User Manual Flow Chart showing how to use the TESTER function of the Digital Console COMBIAG2 ZAPI VO O 48V 350A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General menu MAIN MENU 3 The Display will show PARAMETER GHANGE 4 Press ROLL UP or ROLL DOWN button until TESTER MENU appear on the display 5 The Display shows 6 Press ENTER to go into the TESTER function 7 The first variable to be tested is shown on the MOTOR VOLTAGE Display 8 Press either ROLL UP or ROLL DOWN buttons until your desired variable for measurement appears on the Display 9 When you have finished Press OUT 10 The Display shows 11 Press OUT again and return to Opening Zapi Display MAIN MENU TESTER 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 AFOZPOBA COMBIAC2 User Manual Page 51 65 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 control
19. 24 8 ON o f DN ER RA EFTAB COMBIAC2 CONTROLLER CONNECTORS 9 CONN A AMPSEAL 8 POLES CONN B MOLEX SPOX 8 POLES CONN C AMPSEAL 35 POLES THIS DRAWING IS A ZAPI s p a PROPERTY ITS REPRI S PROHIBITED EXCEPT FO WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS THAT RELATIVE TO THE REPAIRS OF ZAPI PRODUCTS COMBIAC2 CONTROLLER FUNCTIONAL DRAWING STANDALONE CONFIGURATION IZI DOAN PI Data Dote Tecnico Technicion FF File File Disegno n Drawing n Pagina Poge spa i Ad 42028 POVICLIO ITALY 1 1 Page 30 65 AFOZPOBA COMBIAC2 User Manual 8 PROGRAMMING amp ADJUSTMENTS USING DIGITAL CONSOLE 8 1 Adjustments via Console Adjustment of Parameters and changes to the inverter s configuration are made using the Digital Console The Console is connected to the B connector of the inverter ez Description of Console amp Connection CONNETTORE B DELL INVERTER pDoooo Ivo CONNETTORE CONSOLE 7 A N DISPLAY 1 PARAM IMAX B REVERSE BRAKING COMPENS s R BRAKE amp TESTER MAX SP SPEED I e S P I SPEED II 3 SAVE S P II SPEED III BYPASS FIELD WEAK 4 RESTORE ior or S TEMP V BATT 5 ALARMS V MOT VMN MOT M SW TEST 6 ACCELERATOR 7 MOTOR DATA tt OF Et 3 ROLL ENTER SET PULSANTI 3pm ROLL OUT SET JE D a zm Digital consoles us
20. 5 ae 3 The Display will show MAIN MENU PARAMETER GHANGE 4 Press ENTER to go into the Parameter Change facility 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 RELEASE BRAKING Display LEVEL 5 8 When the desired Parameter appears the Display will show a Level Number that will be Between 0 and 9 Press either PARAM Top Right ors or SET Bottom Right buttons to change the Level value RELEASE BRAKINCG LEVEL 6 10 When you are satisfied with the results of the Oda changes you have made Press OUT OMO 11 The Display asks ARE YOU SURE ied a alid YES ENTER NO OUT 9 The Display will show the New Level 12 Press ENTER to accept the changes or press OUT if you do not wish to accept the changes and wish to make further modifications to the parameters MAIN MENU PARAMETER GHANGE 13 The Display will show AFOZPOBA COMBIAC2 User Manual Page 45 65 8 6 COMBIAC2 and COMBIAC2 Power programming console functions Functional configuration see 8 4 Parameter programming see 8 5 Tester user can verify the state of the following parameters TRACTION PUMP motor voltage 96 motor voltage 96 frequency Hz frequency Hz encoder Hz encoder Hz slip value Hz slip value Hz current rms A current rms A temperature C temperatu
21. C T aa alk 8 kHz External temperature range n 30 C 40 C Maximum inverter temperature at full power 75 C 22 Block diagram COMBIAC2 Page 6 65 AFOZPOBA COMBIAC2 User Manual 2 3 Technical specifications COMBIAC2 Power 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 AC motor Voltage m E c ES 24 36 48 72 80V Maximum current 24 V sessse 500 A RMS for 3 per each motor Maximum current 36 48 V 450 A RMS for 3 per each motor Maximum current 72 80 V 400 A RMS for 2 per each motor ie oleae in bana ikok an ennet 8 kHz External temperature range 30 C 40 C Maximum inverter temperature at full power 75 C 24 Block diagram COMBIAC2 Power See chapter 2 2 AFOZPOBA COMBIAC2 User Manual Page 7 65 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The COMBIAC2 needs some external parts in order to work The following devices complete the kit for the COMBIAC2 installation 3 1 Microswitches The microswitch
22. Correct Layout Module 2 Center of the Ground connection Module 3 Note Module 1 power Module 2 power gt Module 3 power 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 E 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 Page 14 65 AFOZPOBA COMBIAC2 User Manual lower costs less and smaller cables improved reliability fewer connections analysis of problems improved easy connection with a pc to read the data flowing through the cable 4 2 4 Wirings I O connections 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 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 multi
23. ERM R PTHERM R NLC PLC NBRAKE PBRAKE PAUX NAUX BATT PPOT NTHERM L PTHERM L AFOZPOBA COMBIAC2 User Manual V 12 V Negative of traction motor encoder power supply Connected to 4Batt trough a microswitch and a 10 A fuse in series Common of FW REV LIFT ENABLE PB SEAT ENABLE microswitches Seat presence signal active high Forward direction request signal active high Reverse direction request signal active high Traction request signal active high Pedal brake request signal active high Lift request signal active high Positive of pump motor encoder power supply 5 V 12 V Negative of pump motor encoder power supply Traction motor encoder phase A Traction motor encoder phase B Negative of lift potentiometer BATT Positive of lift potentiometer 5 V 12 V Lift potentiometer wiper signal Brake potentiometer wiper signal BATT Negative of traction accelerator potentiometer tested for wire disconnection diagnosis Traction potentiometer wiper signal Pump motor encoder phase A Pump motor encoder phase B Negative of traction motor temperature sensor Traction motor temperature signal Output of main contactor coil driver drives to BATT Positive of main contactor coil Output of electric brake coil drives the load to BATT maximum current 3 A Positive of the electromechanical brake coil Positive of auxiliary load Output of auxiliary load driver d
24. K The test is carried out continuously An alarm is signalled when a double running request is made simultaneously Possible causes A defective wiring B running microswitch failure C incorrect operation if the defect persists replace the logic 23 THERMIC SENSOR KO The range of inverter temperature sensor is always checked and a warning is signalled if it is out of range When this alarm is signalled the maximum current of the controller is reduced to halt 24 WAITING FOR NODE 45 The Pump has detected a failure the Traction cannot close the main contactor because of the alarm status of the Pump which the Traction knows by the CAN BUS line The failure must be looked for in the Pump controller use the remote console to get connection to the Pump uC 25 WAITING FOR NODE 3 The Traction uC has detected a fault condition the Pump is aware of this thanks to canbus communication it cannot drive the motor until the Traction has resolved its problem The fault has to be looked for in the Traction 26 NO CAN MESSAGE 5 Traction node 3 signals that it has lost can communication with the Pump node 5 This fault could be determined by a problem in the truck canbus line or by an internal problem in the controller logic card It is suggested to preliminary check canbus connection 27 NO CAN MESSAGE 3 Pump node 5 signals that it has lost can communication with the Traction node 3 This fault could be determined by a problem i
25. ONSOLE 31 8 1 Adjustments via Console sineret tenir a a arta aene aaa akal 31 AFOZPOBA COMBIAC2 User Manual Page 3 65 10 11 12 8 2 Description of Console amp Connection 31 8 3 Description of COMBIAC2 and COMBIAC2 Power Standard Console Menu 32 8 3 1 Traction configuration eiue redd aera ceca edet ee de bcUo S ke leban 32 8 3 2 Pump Coren Ura Oni nasa RU 33 8 4 COMBIAC2 and COMBIAC2 Power function configuration 34 os A218 0 9 NE oom 34 e E QU cM P EE 36 8 5 COMBIAC2 and COMBIAC2 Power parameter regulation 42 BS G21 510 A uiui editae eee m aaa 42 892 icm c m 44 8 6 COMBIAC2 and COMBIAC2 Power programming console functions 46 8 7 Sequence for Ac Inverter Traction setting 46 8 8 Sequence for Ac Inverter Pump setting a 47 8 9 Tester description of the COMBIAC2 and COMBIAC2 Power function 48 BS TIDSPUODLunseu a a A re 48 ee eee er eee nee eo er en eee ee ee ee ere 48 OTHER gle 6 BS t 51 9 1 Save and Restore function soos ars RC E 51 9 2 Description of Alarms IMENU vin nei o oe o dete bs hu sede aa NE Gedas euenit 51 9 3 Description of Console Program Vacc function 52 COMBIAC2 INVERTER DIAGNOSTIC e nana nannnna nana nana nana na 54 NEL se a A o a A NERES 54 10 2 Analysis of alarms displayed on
26. V Azam ELECTRONIC OLEODYNAMIC INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma 59 42028 POVIGLIO RE ITALY Tel 39 0522 960050 r a Fax 39 0522 960259 e mail zapi zapispa it web www zapispa it User Manual COMBIAC2 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 VA MAP is a registered trademark property of Zapi S p A NOTES LEGEND EY The symbol aboard is used inside this publication to indicate an annotation or a suggestion you should pay attention A The symbol aboard is used inside this publication to indicate an action or a characteristic very important as for security Pay special attention to the annotations pointed out with this symbol Page 2 65 AFOZPOBA COMBIAC2 User Manual Contents 1 INTRODUCTION
27. alue of the motor current 6 TEMPERATURE The temperature measured on the aluminum heat sink holding the MOSFET devices 7 MOTOR TEMPERAT This is the temperature of the pump motor if the option is programmed None see chapter 8 4 2 it shows 0 8 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 9 BATTERY VOLTAGE Level of battery voltage measured at the input of the key switch 10 SEAT SWITCH The level of the Seat Microswitch digital input ON VB input active switch closed OFF GND input non active switch opened 11 FORWARD SWITCH The level of the Forward direction digital input FW ON VB input active switch closed OFF GND input non active switch opened AFOZPOBA COMBIAC2 User Manual Page 49 65 Page 50 65 12 BACKWARD SWITCH The level of the Reverse direction digital input BW ON VB input active switch closed OFF GND input non active switch opened 13 ENABLE SWITCH The level of the Enable digital input ON VB input active switch closed OFF GND input non active switch open 14 LIFTING SWITCH Status of the lifting switch ON VB active entry of closed switch OFF GND non active entry of open switch 15 HYDRO SPEED REQ Status of the hydro speed request of the pump ON VB input active switch closed OFF GND input non active switch open
28. amy y C FANS Z i s Te di AMPSEAL Plug P N 776164 4 CONNECTOR CONSOLE MOLEX AMPSEAL Plug P N 776286 1 m P N 09 50 1081 7 due p LO X 9 cih AFOZPOBA COMBIAC2 User Manual 7 2 Connection drawing standalone COMBIAC 2 and COMBIAC2 Power A B E D E F G H K 0 10A FUSE BA d TO M Ts ey VR D V JMD I A wm 1 z CANH CANT H 4 CAN POS i CANL DUT CNA CANT I ni CANL CANH IUI 7 BATI 5 CAN NEG S 8 AT s 1 PUMP AC JS 3 00 ZARIS MOTOR E HANDSE x CNB E e N s 4 FLASH a E e pa SV WS 8 PR GRAMMING e WS 8 m a KEY SWITCH A STAT E A EW 4 n t S LIFT ENABI BT B EN ACE i E A REV l PENC 9 v dej ENC UIT M CMM C MENG AL 12 CNC peat zu P n 33 i FE CNC C ACC BRAKE i Z emu PADS e LEPOT a Acc BRAKE B PTHER EC n NPDT 35 5 n NTHERM L ig SP TRR 1g BaT 31 NAUX BA AUX A JM 30 EAUX ARE TRACTIUN AC P g NER MOTOR EB 6 5 7 es PE naan aL A Gy VM EB COIL BHi Re TC z sj v PLC SCARE 1 os NEC LC COIL LIFT POT je PPOT LIFT NS NPOT FI s LINPDT LI EE M 17 LJEPOT LIFT a PENC_RIT ge a Rell NENC_R up PHA_RI 45 N xig gll CNC 14 PTHERM_R _ NTHERM
29. anual The level of the Seat Microswitch digital input ON VB input active switch closed OFF GND input non active switch open 13 CUTBACK SWITCH The level of the Speed Reduction Microswitch ON GND input active switch opened OFF VB input non active switch closed 14 BRAKE SWITCH The level of the Pedal Brake Microswitch ON VB input active switch closed OFF GND input non active switch open 15 BRAKE PEDAL POT The percentage of the pressure on the brake pedal 10096 if the pedal is totally pressed 0 if the pedal is released 16 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 17 BATTERY VOLTAGE Level of battery voltage measured at the input of the key switch 18 BATTERY CHARGE The percentage Charge level of the battery 8 9 2 Pump 1 MOTOR VOLTAGE This is the voltage supplied to the motor by the inverter it is expressed as a percentage of the full voltage which depends of the battery voltage 2 FREQUENCY This is the frequency of the voltage and current supplied to the motor 3 ENCODER This is the speed of the motor expressed in the same unit of the frequency this information comes from the speed sensor 4 SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor expressed in the same unit of the frequency 5 CURRENT RMS Root Mean Square v
30. at rest in combination with a couple of Travel demand switches On reguest it is also possible the handling in the right side of next figure potentiometer in the middle at rest still in combination with a couple of Travel demand switches Page 8 65 AFOZPOBA COMBIAC2 User Manual 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 3 3 Other analog control unit 1 Input C18 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 kohm range Generally the load should be in the 1 5 mA to
31. ate 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 AFOZPOBA COMBIAC2 User Manual 2 3 A SOURCE OF EMISSIONS finding the main source of disturb and work on it B SHIELDING enclosing contactor and controller in a shielded box using shielded cables C LAYOUT a good layout of the cables can minimize the antenna effect cables running nearby the truck frame or in iron channels connected to truck frames is generally a suggested not expensive solution to reduce the emission level ELECTROMAGNETIC IMMUNITY The considerations made for emissions are valid also for immunity Additionally further protection can be achieved with ferrite beads and by
32. ation 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 cre
33. 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 AFOZPOBA COMBIAC2 User Manual Page 61 65 Page 62 65 10 PEDAL WIRE KO This alarm is signalled if a fault is detected in the accelerator unit wiring NPOT or PPOT cable is interrupted 11 WRONG SET BATTERY When the key is turned ON the controller check the battery voltage and compares it with the SET BATTERY parameter setting If the actual value is 2096 higher or lower than nominal value the fault condition is entered Replace the battery with a correct battery 12 PUMP KO Pump and traction uCs perform a cross check in order to verify their functionality If the Traction detects Pump uC malfunctioning it brings the controller in a safe status opening the power bridge and the Line Contactor 13 MASTER KO Pump and Traction uCs perform a cross check in order to verify their functionality There are two conditions under which p
34. 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 g EMC A EMC and ESD performances of an electronic system 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 Zapi can offer assistance and suggestions based on its years experience on EMC related items However ZAPI declines any responsibility for non compliance malfunctions and failures if correct testing is not made The machine AFOZPOBA COMBIAC2 User Manual Page 17 65 Page 18 65 manufacturer holds the responsability to carry out machine validation based on existing norms EN12895 for industrial truck EN50081 2 for other applications 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 propag
35. e alarm CHARGE capacitor voltage condition 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 74 DRIVER X X X X Alarm line If the alarm is present SHORTED contactor coil in Init status remove driver is shorted the alarm cause If the alarm has occurred in stby or running mode it is necessary to remove alarm cause and to activate traction request 75 CONTACTO X X X Alarm line To remove alarm R DRIVER contactor coil cause and to activate driver is open not traction request able to drive the coil to the correct voltage Page 56 65 AFOZPOBA COMBIAC2 User Manual Co ALARM Tra Pump CONTROLLER DESCRIPTION Condition that has to de STRING ctio STATUS occur to come out n from alarm status Init Stby Motor running 76 COIL X X X X Alarm If the alarm is present SHORTED Init the LC and in Init status remove EB coil driver the alarm cause protection circuit If the alarm has is damaged occurred in stby or Stby or running running mode it is short on LC coil necessary to remove or EB coil alarm cause and to activate traction request 37 CONTACTOR X X Alarm line To remove alarm CLOSED contactor power cause within a contact is stuck timeout if the timeout is elapsed it is necessary to re cycle the key 38 CONTACTOR X X Alarm line To remove alarm OPEN
36. ed to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA minimum Release Number 3 02 AFOZPOBA COMBIAC2 User Manual Page 31 65 8 3 Description of COMBIAC2 and COMBIAC2 Power Standard Console Menu 8 3 1 Traction configuration HEADING AIN MENU m PARAMETER ACCELERATION DELAY 0 9 SET MODEL r4 CHANGE RELEASE BRAKING 029 NVERS BRAKING 0 9 PEDAL BRAKING 0 9 SPEED LIMIT BRAKING 0 9 BRAKE CUTBAC 0 9 SET OPTIONS 71 MAX SPEED FORW iz MAX SPEED BACK Hz CUTBACK SPEED 1 Z FREQUENCY CREEP Hz MAXIMUM CURRENT 0 9 ACC SMOOTH NV SMOOTH STOP SMOOTH Hz AUXILIARY TIME Sec TESTER MOTOR VOLTAGE FREOUENCY Hz ADJUSTMENTS ENCODER iz SLIP VALUE Hz CURRENT RMS A TEMPERATURE C OTOR TEMPERAT C ACCELERATOR V FORW SWITCH ON OFF BACK SWITCH ON OFF ENABLE SWITCH ON OFF SEAT SWITCH ON OFF CUTBACK SWITCH ON OFF BRAKE SWITCH ON OFF BRAKE PEDAL POT Z VOLTAGE BOOSTER X BATTERY VOLTAGE V BATTERY CHARGE z SAVE PARAMETER RESTORE PARAMETER ALARMS ar WN V PROGRAM v T VACC SETTING MIN MAX 7 NOT MOTOR DATA AVAILABLE Page 32 65 CONNECTED TO 3 HOUR COUNTER RUNNING KEY ON BATTERY CHECK ON OFF TRACTION CUTOUT ON OFF LIFT CUTOUT ON OFF HYDRO KEY ON ON OFF STOP ON RAMP ON OFF PEDAL BRAKING SET TEMPERATURE SMART DISPLAY ANALOC DIGITAL ANALOG DIGITAL NONE
37. elled and replaced by the default values 17 HIGH TEMPERATURE Traction or Pump or both temperatures are greater than 75 C The maximum current is reduced proportionally to the temperature increase At 100 C the max current of both inverter is reduced to zero If the alarm is signalled when the controller is cold A thermal sensor failure B failure in the logic card 18 MOTOR TEMPERATURE This warning is signalled if traction or pump or both motors temperature switches open digital sensor or if the analog signals overtakes the cut off level If it happens when the motor is cold check the wiring If all is ok replace the logic board 19 BATTERY LOW If the battery check option is ON a battery discharge algorithm is carried AFOZPOBA COMBIAC2 User Manual out When the charge level is 20 this alarm is signalled and the current is reduced to the half of the programmed level 20 VACC NOT OK The test is made in standby This alarm indicates that the accelerator voltage is 1 V greater than the minimum value programmed by the PROGRAM VACC function Possible causes A the potentiometer is not correctly calibrated B the potentiometer is defective 21 INCORRECT START This alarm signals an incorrect starting sequence Possible causes A Fw or Rev or Enable microswitch failure B error in sequence made by the operator C incorrect wiring if the default persists after checking the harness replace the logic 22 FORW BAC
38. ensor is connected to C35 input ANALOG an analog motor thermal sensor is connected to C35 the curve can be customized on a customer request NONE no motor thermal sensor switch is connected SUBMENU ADJUSTEMENT 1 THROTTLE 0 ZONE It establishes a deadband in the accelerator input curve see also curve below 2 THROTTLE X POINT These parameter change the characteristic of the accelerator input curve 3 THROTTLE Y POINT These parameter change the characteristic of the accelerator input curve Page 36 65 AFOZPOBA COMBIAC2 User Manual VACC MIN and VACC MAX are values programmable by the Program Vacc function 4 AUX OUPUT VOLTAGE This parameter adjust the voltage of the auxiliary output coil hydraulic steering contactor coil PWM output C31 AFOZPOBA COMBIAC2 User Manual Page 37 65 Flow chart showing how to make changes to OPTION Menu 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter SET Menu 3 The Display will show SET MODEL 4 Press ROLL UP or ROLL DOWN button until SET MODEL Menu appears 5 SET OPTIONS appears on the display 6 Press ENTER to go into the SET MODEL Menu 7 The display will shows the first OPTION 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 order to modify the changes 11 New OPTION appears 12 Press OUT to exit the Menu 13 Confirmation reque
39. es ERR La rh cet 16 4 3 Protection and safety features 16 4 3 1 Protection SAME nei ele 16 DER cua 0 S avre rake Pok a ka aa ala alko adi vana bana 17 s cec ENI AE NA am 17 4 5 Various suggestions ae aeranta aloe SEEN npa ea lab neke 19 5 OPERATIONAL FEATURES 5aisinackssntnckku ja ke kanala PR Rubr PA 0a FRAN OMEN EAM P E 20 5 1 i is me NT ANI 20 6 DESCRIPTION OF THE CONNEGCTOR GS sbeteothnai tana roo Kt r aa oA na ER aaa iR nrw PA kabla Rata GRE 22 6 1 Connectors of the logic COMBIAC2 e COMBIAC2 Power 22 6 2 CANBUS connector description 24 6 2 1 COMBIAC 2 Controller in stand alone configuration 24 6 2 2 COMBIAC 2 Controller is a termination module in the canbus net 24 6 2 3 COMBIAC2 Controller is a repetition module in the canbus net 25 6 3 Description of power connections eessesssssseeeeeeeneeeeee nennen nnne 26 iv ME eR I Pour 26 6 3 2 COMBIAC2 Power issues sentier itta Etenim titer ine ea ane 27 T DRAWINGS incinin ia aaa aaia 28 7 1 Mechanical drawing e TE 28 7 1 1 Dimensions of 68 5 o gmmmmama z lt 28 7 1 2 Dimensions of COMBIAC2 Power 29 7 2 Connection drawing COMBIAC2 and COMBIAC2 Power standalone 30 8 PROGRAMMING 8 ADJUSTMENTS USING DIGITAL C
40. es must have a contact resistance lower than 0 1 ohm and a leakage current lower than 100 pA 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 function request for ex running request is made 3 2 Analog unit The accelerator the brake and the lift command unit can consist of a potentiometer or an Hall effect device It should be in a 3 wire configuration The accelerator brake and lift potentiometer are supplied respectively through CNC 33 CNC 33 e CNC 16 It can be either a 5 V output or a 10 V output The selection of the output voltage is made in the logic card by moving a jumper factory set Accelerator brake and lift potentiometer output signal must be input respectively to CPOT CNC 21 CPOTBRK CNC 18 and CPOTLIFT CNC4 7 signal range is from 0 to 10 V The negative supply of the accelerator brake and lift potentiometer has to be taken respectively from CNC 20 CNC 19 and CNC 15 CNC 20 output NPOT is feedback to the uC A D converter to test the continuity of the accelerator unit circuit test of poti wire disconnection Potentiometers value should be in the 0 5 10 Kohm range generally the load should be in the 1 5mA to 30 mA range Faults can occur if it is outside this range The standard connection for the potentiometer is the one in the left side of next figure potentiometer on one end
41. is sufficient a simple double wire cable or a duplex cable not shielded na 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 A Wrong Layout Module 1 Module 3 The red lines are can wires The black boxes are different modules for example traction controller pump controller and display connected by canbus The black lines are the power cables This is apparently a good layout but can bring to errors in the can line The best solution depends on the type of nodes modules connected in the network If the modules are very different in terms of power then the preferable connection is the daisy chain AFOZPOBA COMBIAC2 User Manual Page 13 65 A Correct Layout Module 2 Module 3 Note Module 1 power gt Module 2 power gt Module 3 power 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 A
42. ivate traction request 13 EEPROMKO X X X X X Warning Eeprom To remove Warning fault controller cause will use default parameters 61 HIGH X X X X X Warning Traction To remove Warning TEMPERA or Pump or both cause TURE temperature higher than 75 C 65 MOTOR X X X X X Warning Traction To remove Warning TEMPERA or Pump or both cause TURE motors temperature high 66 BATTERY X X X X Warning battery To remove Warning LOW charge level cause below 2096 Page 58 65 AFOZPOBA COMBIAC2 User Manual Co ALARM STRING 5 Oo ID o Pump CONTROLLER STATUS DESCRIPTION Condition that has to occur to come out from alarm status Init Stby Motor running 78 VACC NOT OK X X Warning accelerator signal CPOT voltage higher than VACC MIN 1V while the traction enable switch is open To remove Warning cause 79 INCORRECT START Warning wrong traction request sequence To remove Warning cause 80 FORWARD BACKWARD Warning forward and reverse inputs are both active To remove Warning cause 249 THERMIC SENSOR KO Warning Traction or Pump temperature sensor is out of range To remove Warning cause 251 WAITING FOR NODEH5 Warning Traction UC signals that Pump uC is in alarm status To remove Warning cause 251 WAITING FOR NODE 3 Warning Pump UC signals that Traction uC is in alarm s
43. ked every 3 months Check the Battery cables cables to the chopper 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 AFOZPOBA COMBIAC2 User Manual Page 65 65
44. ler 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 9 2 Description of Alarms menu Page 52 65 The microprocessor in the controller records the last five Alarms that have occurred Items remembered relative to each Alarm are the code of the alarm the number of times the particular Alarm occurred the Hour Meter count and the chopper temperature This function permits a deeper diagnosis of problems as the recent history can now be accessed ia the Digital Console COMBIAG2 ZAPI VO O 48V 350A 00000 Flow Chart showing how to use the ALARMS function v 1 Opening Zapi Display nM Mami 2 Press ENTER to go into the General menu E EIE 3 The Display will show MAIN MENU PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until NOG PARAMETER CHANGE appears on the display goa MAIN MENU ALARMS 0E O ood CODE 00005 02 20 C 5 The Display will show 6 Press ENTER to go into the ALARMS function 7 The Display will show the most recent Alarm 8 Each press of the ROLL UP button brings up following Alarms Pressing ROLL DOWN returns to the most recent CODE 00007
45. meter 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 4 2 5 Encoder installation 1 Combiac2 card is fit for different types of encoder To control AC motor with Zapi inverter it is necessary to install an incremental encoder with 2 phases shifted of 90 The encoder power supply can be 5 or 12V It can have different electronic output C11 C1 45V 412V positive of encoder power supply C12 C2 GND negative of encoder power supply C22 C13 A phase A of encoder C23 C14 B phase B of encoder 2 Connection of encoder with open collector output 5V power supply 3 Connection of encoder with open collector output 12V power supply A 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 AFOZPOBA COMBIAC2 User Manual Page 15 65 the logic unit must be set in the correct way by Zapi 4 2 6 Main contactor and key connection 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
46. ms 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 Page 20 65 The microcontrollers continually monitor the inverter and carry out a diagnostic procedure on the main functions The diagnosis is made in 4 points 1 2 3 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 uCS integrity of safety related inputs hardware Standby diagnosis in stby that checks watchdog circuit phase s voltages contactor driver current sensor can bus interface Diagnosis during operation that checks watchdog circuits contactor driver AFOZPOBA COMBIAC2 User Manual current sensors can bus interface 4 Continuos 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 AFOZPOBA COMBIAC2 User Manual Page 21 65 6 DESCRIPTION OF THE CONNECTORS g Connectors of the logic COMBIAC2 e COMBIAC2 Powe
47. n the truck canbus line or by an internal problem in the controller logic card It is suggested to preliminary check canbus connection 28 PUMP WARNING This is a warning in the Traction controller which inform that the Pump is ina pump chopper related fault condition 29 PUMP INC START This is a warning in the Pump controller which inform that an incorrect start sequence happened on the pump 30 PUMP VACC NOT OK This is a warning in the Pump controller which inform that lift potentiometer voltage is 1V greater than the minimum value programmed AFOZPOBA COMBIAC2 User Manual Page 63 65 11 RECOMMENDED SPARE PARTS FOR INVERTER Page 64 65 Part Number Description C16507 Protected 500 A strip Fuse C16505 Protected 355 A strip Fuse C16520 6 3 A 20 mm Control Circuit Fuse C29523 SW 180 80 V Single Pole Contactor C29522 SW 180 48 V Single Pole Contactor C29508 SW 180 24 V Single Pole Contactor AFOZPOBA COMBIAC2 User Manual 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 chec
48. no 5s o iss 200 frequency creer m os oe os 12 25 is 22 25 or 29 paxmeconrvr simax e so se e e s n Keson obzir 2a as 27 9 55 mvsuwom esse vs o i2 i5 i7 20 25 30 xu nw se o oz os oso Bs E T2 TETE 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 AFOZPOBA COMBIAC2 User Manual Page 43 65 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 8 5 2 Pump The following parameters can be modified 1 ACC DELAY It determines the acceleration ramp 2 DEC DEALY It determines the deceleration ramp 3 MAX SPEED LIFT It determines the maximum lifting speed 4 MIN SPEED LIFT Minimum speed when the lift enable switch is closed but the lift potentiometer is on a minimum position 5 HYD SPEED FINE Hydraulic steering speed fine regulation 6 CUTBACK SPEED Speed reduction when the cutback switch is active 7 MAXIMUM CURRENT This changes the maximum current of the inverter 8 AUXILIARY TIME Time delay when an hydraulic
49. oft 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 Make the choice for the truck behaviour on a slope see chapter 8 4 1 If the Stop on ramp option is ON set the desired value of auxiliary time parameter 17 Set SET TEMPERATURE setting the motor thermal sensor type used 18 Set MAIN CONT VOLTAGE setting the main contactor coil voltage 8 8 Seguence for Ac Inverter Pump setting When the Key Switch is closed if no alarms or errors are present the Console Display will be showing the Standard Zapi Opening Display If the controller is not configured to your reguirements follow the seguence detailed here following Remember to re cycle the Key Switch if you make any changes to the controller s configuration 1 Select the Options required See Chapter 8 4 2 2 Select and set the Battery Voltage See Chapter 8 4 2 3 Confirm correct installation of all wires Use the Console s TESTER function to assist 4 Perform the lift signal acquisition procedure using the Console PROGRAM VACC
50. pass capacitors ELECTROSTATIC IMMUNITY Three ways can be followed to prevent damages from ESD A PREVENTION when handling ESD sensitive electronic parts ensure the operator is grounded test grounding devices on a daily basis for correct functioning this precaution is particularly important during controller handling in the storing and installation phase B ISOLATION use anti static containers when transferring ESD sensitive material C GROUNDING when a complete isolation cannot be achieved a good grounding can divert the discharge current trough a safe path the frame of a truck can works like a local earth ground absorbing excess charge So it is strongly suggested to connect to truck frame all the parts of the truck which can be touched by the operator who is most of the time the source of ESD 4 5 Various suggestions 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 During battery charge disconnect ASYNCHRONOUS from the battery AFOZPOBA COMBIAC2 User Manual Page 19 65 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
51. 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 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 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 alar
52. potentiometer The minimum intensity is established by the Release braking parameter when the brake pedal is slightly pressed brake switch close but brake potentiometer at the minimum The maximum intensity is established by the Pedal braking parameter when the brake pedal is fully pressed brake potentiometer at the maximum In the middle positions the electrical braking intensity is a linear function between minimum and maximum intensity DIGITAL The truck does not have a potentiometer installed on the mechanical brake pedal but only a microswitch when the accelerator pedal is released and the brake pedal is pushed brake switch closed the inverter performs an electrical braking following Pedal braking parameter 8 SET TEMPERATURE DIGITAL a digital ON OFF motor thermal sensor is connected to C25 input ANALOG an analog motor thermal sensor is connected to C25 the curve can be customized on a customer request NONE no motor thermal sensor switch is connected AFOZPOBA COMBIAC2 User Manual 9 SMART DISPLAY ON OFF ifthis option is programmed ON the communication with the Smart display is active SUBMENU ADJUSTEMENT 1 2 3 4 5 6 7 8 9 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
53. power block module varies and is dependent on the current drawn and the duty cycle 4 2 2 Wirings power cables A The power cables length must be as short as possible to minimize power losses They must be tightened on controller power posts with a Torque of 13 15 Nm The COMBIAC2 module should only be connected to a traction battery Do not use converters outputs or power supplies For special applications please contact the nearest Zapi Service Centre Do not connect the controller to a battery with a nominal voltage different than the value indicated on the controller label A higher battery voltage may cause power section failure A lower voltage may prevent the logic operating 4 2 3 Wirings CAN connections and possible interferences EY Page 12 65 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 AFOZPOBA COMBIAC2 User Manual CAN Controller NE Transceiver 12042 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
54. r A1 CAN H High level CANBUS A2 CANT H CANBUS termination output 120 ohm internally connected to CAN H Connect to CAN L OUT to insert the termination A3 CAN POS Positive of CAN circuit to be used in case of optoisolated CANBUS A4 CAN_L_OUT Low level CANBUS to be used as repetition for CAN L line or to be connected to CANT H to insert termination resistance A5 CANT L CANBUS termination output 120 ohm internally connected to CAN L Connect to CAN H OUT to insert the termination A6 CAN L Low level CANBUS A7 CAN_H_OUT High level CANBUS to be used as repetition for CAN H line or to be connected to CANT L to insert termination resistance A8 CAN NEG Negative of CAN circuit to be used in case of optoisolated CANBUS B1 PCLRXD Positive serial reception B2 NCLRXD Negative serial reception B3 PCLTXD Positive serial transmission B4 NCLTXD Negative serial transmission B5 GND Negative console power supply B6 12 Positive console power supply B7 FLASH B8 FLASH C1 PENC_R Positive of traction motor encoder power supply 5 Page 22 65 AFOZPOBA COMBIAC2 User Manual C2 C3 C4 C5 C6 C7 C8 C9 C10 C11 C12 C13 C14 C15 C16 C17 C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34 C35 NENC R KEY CM SEAT FORWARD REVERSE ENABLE PB LIFT ENABLE PENC L NENC L PHA R PHB R NPOTLIFT PPOTLIFT CPOTLIFT CPOTB NPOTB NPOT CPOT PHA L PHB L NTH
55. re C motor temperat C motor temperat C accelerator V voltage booster 96 forw switch ON OFF battery voltage V back switch ON OFF seat switch ON OFF enable switch ON OFF forw switch ON OFF seat switch ON OFF back switch ON OFF cutback switch ON OFF enable switch ON OFF brake switch ON OFF lifting switch ON OFF brake pedal pot 96 hydro speed req ON OFF voltage booster 96 lifting control V battery voltage V battery charge 96 Save function for storing data gt only with Pc console Restore function for downloading parameters to another controller gt only with Pc console Display of the last 5 alarms including hour meter value and temperature at the moment of the alarm Accelerator range programming Records the minimum and maximum useful accelerator stroke values for both direction of running See the console manual for a detailed description of function and parameters 8 7 Sequence for Ac Inverter Traction setting Page 46 65 When the Key Switch is closed if no alarms or errors are present the Console Display will be showing the Standard Zapi Opening Display If the controller is not configured to your requirements follow the sequence detailed here following Remember to re cycle the Key Switch if you make any changes to the controller s configuration 1 Select the Options required See Chapter 8 4 1 2 Select and set the Battery Voltage See Chapter 8
56. rives to BATT Traction potentiometer positive 5 10 V output use load gt 1 kohm Negative of pump motor temperature sensor Pump motor temperature signal Page 23 65 6 2 CANBUS connector description Combiac2 Controller has a canbus interface so it has been designed to work in a can network together with other electronic modules exchanging informations over the canbus network Furthermore the exchange of informations between pump and traction microcontrollers is based on the canbus as well Combiac2 also provides built in can termination resistance which can be connected in different ways as described here following 6 2 1 COMBIAC 2 Controller in stand alone configuration V Bridge 2 4 and 5 7 connect both built in120 ohm can termination resistances 6 2 2 COMBIAC Controller is a termination module in the canbus net Bridge 2 4 connects one built in 120 ohm can termination resistance the second will be connected in another module of the canbus net Page 24 65 AFOZPOBA COMBIAC2 User Manual 6 2 3 COMBIAC Controller is a repetition module in the canbus net COMBIACe ri N 4 b o The canbus built in termination resistances are not inserted AFOZPOBA COMBIAC2 User Manual Page 25 65 6 3 Description of power connections 6 3 1 COMBIAC2 Page 26 65 View of the power bars
57. s a failure C There is a problem in the power section 8 MAIN CONTACTOR ALARMS 1 COIL SHORTED When the key is switched ON the pu Controller checks the LC coil driver shortcircuit protection hardware If it does not react in a correct way to the uC 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 2 DRIVER SHORTED When the key is switched ON the uC 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 3 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 4 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 5 CONTACTOR CLOSED Before driving the LC coil the controller checks if the LC contact is stuck The controller drives the
58. ss SET UP or SET DOWN button in order to increase or decrease respectively Set the value read by an external voltmeter 11 Battery value appears on the display 12 Press OUT to exit the Menu 13 Confirmation request appears 14 Press ENTER to accept the changes or press OUT if you do not accept the changes 15 ADJUSTMENTS Menu appears 16 Press OUT Display now show the Opening Zapi Menu AFOZPOBA COMBIAC2 User Manual COMBIAG2 ZAPI VO O 48V 350A 00000 NOM Ej Er B Bod ood CONFIG MENU ADJUSTMENT OMO EI EI El SET POT BRK MIN O OV Bod Bod ADJUSTMENT BATTERY 82 1V ADJUSTMENT BATTERY 84 5V oo Bo oo ARE YOU SURE YES ENTER NO OUT CONFIG MENU ADJUSTMENT Page 41 65 es COMBIAC2 and COMBIAC2 Power parameter regulation 8 5 1 Traction The following parameters can be modified 1 ACC DELAY It determines the acceleration ramp 2 RELEASE BRAKING It controls the deceleration ramp when the travel request is released 3 INVERSION BRAKING It controls the deceleration ramp when the direction switch is inverted during travel 4 PEDAL BRAKING It determines the deceleration ramp when the travel request is released and the brake pedal switch is closed 5 SPEED LIMIT BRAKING Deceleration ramp when the pedal position is changed but not completely released 6 BRAKE CUTBACK It determines the deceleration ramp when the speed reduction input becomes ac
59. st appears 14 Press ENTER to accept the changes or press OUT if you do not accept the changes 15 SET OPTIONS Menu appears 16 Press OUT again Display now show the Opening Zapi Menu COMBIAG2 ZAPI VO O 48V 350A 00000 CONFIG MENU SET MODEL CONFIG Om m SET OPTIONS MENU oO GO HOUR COUNTER RUNNING Bo Bo BATTERY GO oO CHECK OFF ARE YOU SURE YES ENTER NO OUT CONFIG SET OPTIONS MENU AFOZPOBA COMBIAC2 User Manual Flow chart showing how to make changes to ADJUSTMENT Menu 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG Menu 3 The display will Show SET MODEL 4 Press ROLL UP or ROLL DOWN button until ADJUSTMENTS Menu appears 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will shows SET BATTERY TYPE 8 Press ROLL UP or ROLL DOWN button until the desired parameter is reached 9 The desired parameter is appears 10 Press SET UP or SET DOWN button to modify the adjustment 11 Press OUT 12 Press ENTER to confirm 13 Repeat the same from 5 to 12 points for the other adjustment AFOZPOBA COMBIAC2 User Manual DOMBIAGZ ZAPI VO O 48V 350A 00000 NOM Ej Er B Bod OGOO CONFIG MENU ADJUSTMENTS OMO ENE E BATTERY TYPE 48v Bod Bod TROTTLE O ZONE 3 oo oo EE TROTTLE O ZONE 7 mm NU oo oo Og
60. tatus To remove Warning cause 247 NO CAN MESSAGE 45 Alarm Traction has lost Can communication with the Pump To remove Warning cause 247 NO CAN MESSAGE 3 Alarm Pump has lost Can communication with the Traction To remove Warning cause 242 PUMP WARNING Warning Traction controller signals that Pump uC has detected a fault in the pump chopper To remove warning cause AFOZPOBA COMBIAC2 User Manual Page 59 65 Co ALARM Tra Pump CONTROLLER DESCRIPTION Condition that has to de STRING ctio STATUS occur to come out n from alarm status Init Stby Motor running 243 PUMP INC X X X Warning pump To remove warning START incorrect start cause sequence 244 PUMP VACC X X X Warning pump To remove warning NOT OK accelerator cause voltage is 1V greater than the minimum value programmed 10 2 Analysis of alarms displayed on console 1 2 3 4 5 6 7 Page 60 65 WATCH DOG It is a self diagnosys test within the logic between Traction and Pump ucontrollers This alarm could also be caused by a canbus malfunctioning which blinds Traction Pump communication So before replacing the controller check the canbus LOGIC FAILURE 13 Fault in the hardware section of the logic board which manages the hardware current protection Replace the logic board LOGIC FAILURE 2 Fault in
61. ter it is expressed as a percentage of the full voltage which depends of the battery voltage 2 FREQUENCY This is the frequency of the voltage and current supplied to the motor 3 ENCODER This is the speed of the motor expressed in the same unit of the frequency this information comes from the speed sensor 4 SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor expressed in the same unit of the frequency 5 CURRENT RMS Root Mean Square value of the motor current 6 TEMPERATURE The temperature measured on the aluminum heat sink holding the MOSFET devices 7 MOTOR TEMPERAT This is the temperature of the traction motor if the option is programmed None see chapter 8 4 1 it shows 0 8 ACCELERATOR The voltage of the accelerator potentiometer s wiper CPOT The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 9 FORWARD SWITCH The level of the Forward direction digital input FW ON VB input active switch closed OFF GND input non active switch open 10 BACKWARD SWITCH The level of the Reverse direction digital input BW ON VB input active switch closed OFF GND input non active switch open 11 ENABLE SWITCH The level of the Enable digital input ON VB input active switch closed OFF GND input non active switch open 12 SEAT SWITCH AFOZPOBA COMBIAC2 User M
62. the hardware section of the logic board which manages the phase s voltage feedback Replace the logic board LOGIC FAILURE 1 This alarm signals that the undervoltage overvoltage protection interrupt has been triggered Two possible reasons B Areal undervoltage overvoltage situation happened C Fault in the hardware section of the logic board which manages the overvoltage protection Replace the logic card VMN LOW VMN HIGH The test is carried out during initial diagnosis and in standby Possible causes A problem with the motor connections or the motor power circuit check if the 3 phases are correctly connected check if there s a dispersion of the motor to truck frame B fault in the inverter power section replace the controller STBY HIGH The uCs verify if the feedback of current sensors device output is within the zero current window Possible causes of the alarm C current sensor failure D failure in the logic card first replace the logic card if the defect persists replace the power unit CAPACITOR CHARGE Follows the charging capacitor system AFOZPOBA COMBIAC2 User Manual a 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 ha
63. tive and the motor slow down 7 MAX SPEED FORWARD It determines the maximum speed in forward direction 8 MAX SPEED BACKWARD It determines the maximum speed in backward direction 9 CUTBACK SPEED 1 Not used 10 FREQUENCY CREEP Minimum speed when the forward or reverse switch is closed but the accelerator is on a minimum position 11 MAXIMUM CURRENT This changes the maximum current of the inverter 12 ACC SMOOTH It gives a different form to the acceleration curve in the frequency range 0 Hz to Stop smooth value see the figure below 13 INV SMOOTH It gives a different form to the acceleration curve after a direction inversion in the frequency range 0 Hz to Stop smooth value see the figure below 14 STOP SMOOTH It sets the level of frequency where the smooth effect on the acceleration ramp ends Page 42 65 AFOZPOBA COMBIAC2 User Manual standard f acceleration ramp cm lt 0 4 1 0 2 0 3 5 t 0 4 1 0 2 0 3 5 are some possible values of the Acc Smooth and Inv Smooth parameters see the table below 15 AUXILIARY TIME It determines the time that the truck is hold on the ramp if the stop on ramp option is ON The following table shows the different values at which the parameters can be set UNPE PROGRAMMED LEVEL CE EU 2494 spe om qos EN ANG see puo ss boo za ee so 55 49 44 os paxsmeniw m pe pe ss pue pos a0 ss o ss 2 paxseenev m pes so ss puo ps
64. to a failure of the electronic device or can be dangerous or harmful for the operator items which are important to guarantee system performance and safety 4 1 Material overview Before to start it is necessary to have the reguired material for a correct installation Otherwise a wrong choice of cables or other parts could lead to failures misbehaviour bad performances 4 1 1 Connection cables For the auxiliary circuits use cables of 0 5 mm section For power connections to the motor and to the battery use cables having section of at least 35 mm For the optimum inverter performance the cables to the battery should be run side by side and be as short as possible 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 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 a2 Installation of the hardware A Before doing any operation ensure that the battery is disconnected and
65. ump enters this fault condition A the Pump pC receives incoherent can message from the Traction uC B the Pump uC compares the inputs status and the related Traction operations and find they are not coherent In both cases the Pump brings the controller to a safe status opening the power bridge and the Line contactor 14 INPUT MISMATCH Safety related inputs Fw direction Rev direction accelerator ENABLE SEAT switch are input to both microcontrollers by independent hw circuit The two uCs read these inputs and compare by exchanging related status on the canbus If the Pump uC finds a mismatch between its inputs and Traction inputs it brings the controller to a safe status opening the power bridge and the Line contactor 15 AUX OUTPUT KO The uP checks the driver of the electromechanical brake coil If the status of the driver output does not correspond to the signal coming from the uP the alarm is signalled It is suggested to preliminary check if there is an external short or low impedance pull down between NAUX C31 and BATT If no external cause can be found replace the logic card 16 EEPROM KO Fault in the area of memory in which the adjustment parameters are stored this alarm does not inhibits truck operation but the controller will use default parameters If the defect persists when the key is switched OFF and ON again replace the logic If the alarm disappears remember that the parameters stored previously have been canc
66. w the minimum voltage value stored with 1V 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 4 3 2 Safety Features A A 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 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 Combiac2 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
67. 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 AFOZPOBA COMBIAC2 User Manual Page 11 65 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 chopper using a Resistor between 100hm and 1000hm 4 2 1 Positioning and cooling of the controller Install the chopper 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 A Fit transient suppression devices to the horn solenoid valves and contactors not connected to the controller 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

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