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.
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.
Contents 1 2 3 4 5 6 7 8 INTRODUCTION ...................................................................................................................5 SPECIFICATION ...................................................................................................................6 2.1 Technical specifications..............................................................................................6 2.2 Block diagram ..............................................................................
8.5 9 10 11 12 13 Parameter regulation................................................................................................ 46 8.5.1 Traction....................................................................................................... 46 8.5.2 Pump .......................................................................................................... 47 8.6 Programming console functions ............................................................................... 49 8.
1 INTRODUCTION Within the ZAPIMOS family, the AC-2 FLASH inverter is the model suitable for control of 3.0 kW to 8.0 kW motors. It has been expressly designed for battery electric traction. It is fit for electric truck, golf cars, utility cars.
2 SPECIFICATION 2.1 Technical specifications Inverter for AC asynchronous 3-phase motors Regenerative braking functions Can-bus interface Flash memory (256 Kbytes On-Chip Program Memory) Digital control based upon a microcontroller Voltage:....................................................................... 24 - 36 - 48 - 72 – 80 – 96 V Maximum current (24 V, 36 V):.................................................. 500 A (RMS) for 3' Maximum current (36 V, 48 V):..........................................
3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The AC-2 FLASH inverter needs some external parts in order to work. The following devices complete the kit for the AC-2 FLASH installation. 3.1 Microswitches - - The microswitches must have a contact resistance lower than 0.1 Ω and a leakage current lower than 100 µA. When full load connected, the voltage drop between the key switch contacts must be lower than 0.1 V.
The 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.
F = flash The encoder resolution is given by the last letter in the following list: A = 32 pulses/rev B = 64 pulses/rev C = 80 pulses/rev D = 128 pulses/rev ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 9/72
4 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colours, they mean: 4 U These are information useful for anyone is working on the installation, or a deeper examination of the content These are Warning boxes, they describe: - operations that can lead 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.
4.2 Installation of the hardware U 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. After operation, even with the Key Switch open, the internal capacitors may remain charged for some time.
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: - - U 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.
connection is the daisy chain. U Correct Layout: R Can Bus Power cables Module 1 Module 2 Module 3 R Note: Module 1 power > Module 2 power > 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.
problems that arise from this complexity - simplified design (readily available, multi sourced components and tools) - 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 - U After crimping the cable, verify that all strands are entrapped in the wire barrel.
4) Connection of encoder with open collector output: +12 V power supply. U VERY IMPORTANT It is necessary to specify in the order the type of encoder used, in terms of power supply, electronic output and n° of pulses for revolution, because the logic unit must be set in the correct way by Zapi. 4.2.6 Main contactor and key connection - The connection of the main contactor can be carried out following the drawing in the figure.
4.3 Protection and safety features 4.3.1 Protection features The AC-2 FLASH is protected against some controller injuries and malfunctions: - 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.
detects a failure in the "SAFETY" circuit, the microcontroller itself will bring the machine in a safe status. Suggested connection of "SAFETY" circuit: - STANDALONE CONFIGURATION: it is suggested to connect safety input to the "SEAT" microswitch or to the "DEADMAN" microswitch (it depends on the application); in this way the machine will be brought to a safe status as soon as the operator leaves the machine.
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.
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.
5 OPERATIONAL FEATURES - - - Speed control. Optimum behaviour an a slope due to the speed feedback: the motor speed follows the accelerator, starting a regenerative braking if the speed overtakes the speed set-point. the system can perform an electrical stop on a ramp (the machine is electrically hold on a slope) for a programmable time (see also chapter 8.4). Stable speed in every position of the accelerator. Regenerative release braking based upon deceleration ramps.
contactor driver, current sensor, can-bus interface. 3) Diagnosis during operation that checks: watchdog circuits, contactor driver, current sensors, can-bus interface. 4) Continuous diagnosis that check: temperature of the inverter, motor temperature. Diagnosis is provided in two ways. The digital console can be used, which gives a detailed information about the failure; the failure code is also sent on the CanBus.
6 DESCRIPTION OF THE CONNECTORS 6.1 Connectors of the logic - Traction configuration Page - 22/72 A1 PCLRXD Positive serial reception. A2 NCLRXD Negative serial reception. A3 PCLTXD Positive serial transmission. A4 NCLTXD Negative serial transmission. A5 GND Negative console power supply. A6 +12 Positive console power supply. A7 FLASH It must be connected to A8 for the Flash memory programming. A8 FLASH It must be connected to A7 for the Flash memory programming. B1 -BATT -Batt.
B2 MODE This input allows the customer to select the software for traction or lifting application. Configuration: MODE: Open (not connected) Traction inverter MODE: Close (connected with A5) Pump inverter. C1 CAN-L Low level CAN-BUS voltage I/O. C2 CAN-L-OUT Low level CAN-BUS voltage I/O. C3 CAN-H High level CAN-BUS voltage I/O. C4 CAN-H-OUT High level CAN-BUS voltage I/O. D1÷D6 Incremental ENCODER connector (see chapter 4.2.5). E1 CPOT Accelerator potentiometer wiper.
be disabled. It can also be used as a general purpose input. Page - 24/72 F6 PTHERM Input for motor temperature sensor. F7 CM Common of FW / BW / SR / PB / SEAT / INCHING FW / INCHING BW / EXCLUSIVE HYDRO / ENABLE microswitches. F8 NLC Negative of main contactor coil. F9 NBRAKE Output for driving a brake or an hydraulic steering contactor coil; it drives the load to -Batt maximum current: 3 A. F10 SR/HB Speed reduction (handbrake) input. Active low (switch opened). See also OPTION chapter.
6.2 Connectors of the logic - Pump configuration A1 PCLRXD Positive serial reception. A2 NCLRXD Negative serial reception. A3 PCLTXD Positive serial transmission. A4 NCLTXD Negative serial transmission. A5 GND Negative console power supply. A6 +12 Positive console power supply. A7 FLASH It must be connected to A8 for the Flash memory programming. A8 FLASH It must be connected to A7 for the Flash memory programming. B1 -BATT -Batt.
Configuration: MODE: Open (not connected) Traction inverter MODE: Close (connected with B1) Pump inverter. C1 CAN-L Low level CAN-BUS voltage I/O. C2 CAN-L-OUT Low level CAN-BUS voltage I/O. C3 CAN-H High level CAN-BUS voltage I/O. C4 CAN-H-OUT High level CAN-BUS voltage I/O. D1÷D6 Page - 26/72 Incremental ENCODER connector (see chapter 4.2.5). E1 CPOT Accelerator potentiometer wiper. E2 PPOT Potentiometer positive: 10 V output; keep load > 1 kΩ.
F9 NHYDRO Output for driving an hydraulic steering contactor; it drives the load to -Batt. Maximum current: 3 A. F10 2nd SPEED Input for second speed request; it is active HIGH. F11 GND -Batt. F12 NTHERM -Batt.
6.3 Description of power connections View of the power bars: Page - 28/72 -BATT Negative of the battery. +BATT Positive of the battery. U; V; W Connection bars of the three motor phases; follow this sequence and the indication on the motor.
7 DRAWINGS 7.
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7.
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8 PROGRAMMING & 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 “A” connector of the inverter. 8.2 Description of Console & Connection Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum "Release Number 3.02".
8.3 Description of Standard Console Menu 8.3.
8.3.2 Pump configuration 8.4 Function configuration 8.4.
SUBMENU "SET OPTIONS" 1) HOUR COUNTER - RUNNING: the counter registers travel time only. - KEY ON: 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.
9) AUX FUNCTION - ON/OFF: if this option is programmed ON the traction inverter applies maximum braking and traction torque. 10) ENABLE FUNCTION - PRESENT: input E14 is managed as accelerator enable input. - ABSENT: input E14 is managed as exclusive hydro input.
8) ADJUSTMENT #04 This parameter determines the motor temperature level at which the “Motor temperature” alarm is signalled. The range is from 70 °C to 160 °C with 10 °C steps. This parameter must be adjusted only if the “Set temperature” (menu “Set option”) parameter is programmed “Analog”. 9) ADJUSTMENT #03 This parameter isn't used. 10) ADJUSTMENT #02 It adjust the lower level of the battery discharge table. 11) ADJUSTMENT #01 It adjusts the upper level of the battery discharge table.
AUX OUTPUT BRAKE BRAKE HYDRO CONT. STOP ON RAMP F9 OUTPUT ON -It drives the coil of a electromagnetic brake. -The hydraulic steering function request is sent to the pump inverter by the can-bus link. OFF -It drives the coil of a electromagnetic brake. -The hydraulic steering function request is sent to the pump inverter by the can-bus link. ON -It drives the coil of a hydraulic steering contactor. -The hydraulic steering function request is also sent to the pump inverter by the can-bus link.
Very important: In the combi system (pump + traction), the battery discharge calculation for the complete system is carried out by the traction inverter; the information about the pump inverter consumption is sent on the can-bus line from the pump inverter to the traction inverter. So the correct programming for the "Battery check" option is: traction inverter: ON pump inverter: OFF. 3) SET TEMPERATURE - DIGITAL: a digital (ON/OFF) motor thermal sensor is connected to F6 input.
6) ADJUSTMENT #04 This parameter determines the motor temperature level at which the “Motor temperature” alarm is signalled. The range is from 70 °C to 160 °C with 10 °C steps. This parameter must be adjusted only if the “Set temperature” (menu “Set option”) parameter is programmed “Analog”. 7) ADJUSTMENT #03 This parameter isn’t used. 8) ADJUSTMENT #02 It adjusts the lower level of the battery discharge table. 9) ADJUSTMENT #01 It adjusts the upper level of the battery discharge table.
Flow chart showing how to make changes to OPTION Menu. AC2 ZAPI V0.0 48V 350A 00000 1) Opening Zapi Menu. 2) Press Top Left & Right Buttons to enter SET Menu. 3) The Display will show: SET MODEL. % ' % ' ' ' CONFIG MENU SET MODEL 4) Press ROLL UP or ROLL DOWN button until SET MODEL Menu appears. 5) SET OPTIONS appears on the display. % ' ' ' ' ' CONFIG MENU SET OPTIONS ' % ' ' ' ' 6) Press ENTER to go into the SET MODEL Menu. 7) The display will shows the first OPTION.
Flow chart showing how to make changes to ADJUSTMENTS Menu. 1) Opening Zapi Menu. 2) Press Top Left & 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. AC2 ZAPI V0.0 48V 350A 00000 % ' % ' ' ' CONFIG MENU SET MODEL % ' ' ' ' ' CONFIG MENU ADJUSTMENTS 6) Press ENTER to go into the ADJUSTMENTS Menu. ' % ' ' ' ' 7) The display will shows SET BATTERY TYPE.
Flow chart showing how to use the SET BATTERY TYPE adjustment. AC2 ZAPI V0.0 48V 350A 00000 1) Opening Zapi Menu. 2) Press Top Left & Right Buttons to enter CONFIG Menu. 3) The Display will show: SET MODEL. % ' % ' ' ' CONFIG MENU SET MODEL 4) Press ROLL UP button until ADJUSTMENTS Menu appears. % ' ' ' ' ' 5) ADJUSTMENTS appears on the display. CONFIG MENU ADJUSTMENTS 6) Press ENTER to go into the ADJUSTMENTS Menu. ' % ' ' ' ' 7) The display will show: SET BATTERY TYPE.
Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console. 1) Opening Zapi Menu. AC2 ZAPI V0.0 48V 350A 00000 2) Press Top Left & Right Buttons to enter CONFIG Menu. 3) The Display will show: SET MODEL. % ' % ' ' ' CONFIG MENU SET MODEL 4) Press ROLL UP button until ADJUSTMENTS Menu appears. 5) ADJUSTMENTS appears on the display. % ' ' ' ' ' CONFIG MENU ADJUSTMENTS 6) Press ENTER to go into the ADJUSTMENTS Menu. 7) The display will show the first OPTION.
8.5 Parameter regulation In addition to the input configuration, parameter modification is made directly by ZAPI on customer specifications, or by the customer, making the adjustments using the programming console. 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.
PARAMETER PROGRAMMED LEVEL UNIT 0 1 2 3 4 5 6 7 8 9 ACCELERATION DELAY (*) Sec. 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 RELEASE BRAKING (**) Sec. 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 INVERS BRAKING (**) Sec. 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 PEDAL BRAKING (**) Sec. 5.5 5.0 4.5 4.0 3.5 3.0 2.5 2.0 1.5 1.0 SPEED LIMIT BRAKING (**) Sec. 8.9 8.3 7.7 7.1 6.6 6.0 5.5 4.9 4.4 3.8 BRAKE CUTBACK (**) Sec. 5.5 5.0 4.5 4.0 3.5 3.
6) 1ST SPEED FINE First speed, fine regulation. 7) 2ND SPEED FINE Second speed, fine regulation. 8) 3RD SPEED FINE Third speed, fine regulation. 9) 4TH SPEED FINE Fourth speed, fine regulation. 10) HYD SPEED FINE Hydro speed, fine regulation. 11) MAXIMUM CURRENT The maximum current of the inverter. 12) AUXILIARY TIME Time delay when an hydraulic steering function request is switched off. The following table shows the different values at which the parameters can be set.
Flow Chart showing how to make Programme changes using Digital Console fitted with Eprom CK ULTRA. 1) Opening Zapi Display. AC2 ZAPI V0.0 48V 350A 00000 ' % ' ' ' ' 2) Press ENTER to go into the General Menu. 3) The Display will show: MAIN MENU PARAMETER CHANGE 4) Press ENTER to go into the Parameter Change facility. 5) The Display will show the first parameter. ' % ' ' ' ' ACCEL. DELAY LEVEL = 4 6) Press either ROLL UP and ROLL DOWN to display the next parameter.
encoder (Hz) slip value (Hz) current rms (A) temperature (°C) motor temperat. (°C) accelerator (V) forward switch (ON/OFF) backward switch (ON/OFF) enable switch (ON/OFF) seat switch (ON/OFF) backing f. (ON/OFF) backing b. (ON/OFF) cutback switch (ON/OFF) brake switch (ON/OFF) exclusive hydro (ON/OFF) brakepedal pot.
If the machine is a forklift, check the performance with and without load. 9) 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. 10) 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.
the TESTER function of the console. The Console acts as a multimeter able to read voltage, current and temperature. The following definition listing shows the relative measurements. 8.9.1 Traction 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.
- OFF / +VB = non active entry of microswitch. 16) BRAKE SWITCH The level of the Pedal Brake Microswitch. - ON / +VB = active entry of Brake pedal Microswitch. - OFF / GND = non active entry of microswitch. 17) EXCLUSIVE HYDRO Status of the exclusive hydro input. - ON / +VB = active entry of closed switch. - OFF / GND = non active entry of open switch. 18) BRAKEPEDAL POT. The percentage of the pressure on the brake pedal (100% if the pedal is totally pressed, 0% if the pedal is released).
- OFF / GND = non active entry of open switch. 11) 2ND SPEED SWITCH Status of the second speed switch of the pump. - ON / +VB = active entry of closed switch. - OFF / GND = non active entry of open switch. 12) 3RD SPEED SWITCH Status of the third speed switch of the pump. - ON / +VB = active entry of closed switch. - OFF / GND = non active entry of open switch. 13) 4TH SPEED SWITCH Status of the fourth speed switch of the pump. - ON / +VB = active entry of closed switch.
Flow Chart showing how to use the TESTER function of the Digital Console. 1) Opening Zapi Display. 2) Press ENTER to go into the General menu. 3) The Display will show: 4) Press ROLL UP or ROLL DOWN button until TESTER MENU appear on the display. 5) The Display shows: AC2 ZAPI V0.0 48V 350A 00000 ' % ' ' ' ' MAIN MENU PARAMETER CHANGE % ' ' % ' ' MAIN MENU TESTER 6) Press ENTER to go into the TESTER function. ' % ' ' ' ' 7) The first variable to be tested is shown on the Display.
9 OTHER FUNCTIONS 9.1 Description of the Console “SAVE” function The SAVE function allows the operator to transmit the Parameter values and Configuration data of the inverter into the Console memory. It is possible to load 64 different programmes. The information saved in the Console memory can then be reloaded into another inverter using the RESTORE function. The data that is available via the SAVE function is as follows: - All Parameter Values (PARAMETER CHANGE). - Options (SET. OPTIONS).
12) Press OUT to return to the Opening Zapi Display.
9.2 Description of Console “RESTORE” function The RESTORE PARAM function allows transfer of the Console’s stored data into the memory of the inverter. This is achieved in a fast and easy way using the method previously used with the SAVE PARAM. function. The data that is available via the RESTORE PARAM. function is as follows: - All Parameter Values (PARAMETER CHANGE). - Options (SET OPTIONS). - The level of the Battery (ADJUST BATTERY).
12) You can see the items that are being stored in the inverter memory whilst the RESTORE routine is happening. STORING ACCELER. DELAY 13) When finished the Console displays: MAIN MENU RESTORE PARAM. 14) Press OUT to return to the Opening Zapi Display.
9.3 Description of “ALARMS” menu The microprocessor in the inverter remembers 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 inverter temperature. This function permits a deeper diagnosis of problems as the recent history can now be accessed. Flow Chart showing how to use the ALARMS function via the Digital Console. AC2 ZAPI V0.
9.4 Description of Console “PROGRAM VACC” function This enables adjustment of the minimum and maximum useful signal level, 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 two graphs show the output voltage from a non-calibrated potentiometer with respect to the mechanical “zero” of the control lever.
8) Press ENTER to clear these values. Display will show 0.0. 9) Select Forward Direction, close any interlock switches that may be in the system. ' % ' ' ' ' MIN 0.0 VACC - MAX 0.0 MIN 0.6 VACC ↑ MAX 4.4 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. 11) Select the Reverse Direction and repeat Item 10. ' ' ' ' % ' 12) When finished, press OUT.
10 AC-2 FLASH INVERTER DIAGNOSTIC TRACTION CONFIGURATION The alarms are signalled by a diagnostic LED. 1 blink: logic failure ("WATCHDOG", "EEPROM KO", "LOGIC FAILURE #1", "LOGIC FAILURE #2", "LOGIC FAILURE #3", "CHECK UP NEEDED"). 2 blinks: running request on start-up or error in seat sequence, double direction request or encoder problem ("INCORRECT START", "HANDBRAKE", "FORW + BACK", "ENCODER ERROR"). 3 blinks: phase voltage or capacitor charge failure ("CAPACITOR CHARGE", "VMN LOW", "VMN HIGH").
4) LOGIC FAILURE #2 Fault in the hardware section of the logic board which manages the phase' s voltage feedback. Replace the logic board. 5) LOGIC FAILURE #3 Fault in the hardware section of the logic board which manages the hardware current protection. Replace the logic board. 6) CHECK UP NEEDED This is a warning. It is an information for the user that the programmed time for maintenance is elapsed. 7) INCORRECT START This alarm signals an incorrect starting sequence.
12) 13) 14) 15) 16) 17) 18) A) the charging resistance is opened; if it is opened. B) The charging circuit has a failure. C) There is a problem on the power modules. 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 towards ground; B) inverter failure, replace it.
- 19) 20) 21) 22) 23) 24) 25) 26) 27) 28) 29) Page - 66/72 CONTACTOR CLOSED The controller checks if the LC contact is closed when the coil isn’t driven, 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 or pasted. AUX OUTPUT KO The µP checks the driver of the electromechanical brake.
11 AC-2 FLASH INVERTER DIAGNOSTIC PUMP CONFIGURATION The alarms are signalled by a diagnostic LED. 1 blink: logic failure ("WATCHDOG", "EEPROM KO", "LOGIC FAILURE #1", "LOGIC FAILURE #2", "LOGIC FAILURE #3"). 2 blinks: running request on start-up, error in seat sequence or encoder problem ("INCORRECT START", "ENCODER ERROR"). 3 blinks: phase voltage or capacitor charge failure ("CAPACITOR CHARGE", "VMN LOW", "VMN HIGH"). 4 blinks: failure in accelerator ("VACC NOT OK", "PEDAL WIRE KO").
4) LOGIC FAILURE #2 Fault in the hardware section of the logic board which manages the phase' s voltage feedback. Replace the logic board. 5) LOGIC FAILURE #3 Fault in the hardware section of the logic board which manages the hardware current protection. Replace the logic board. 6) INCORRECT START This alarm signals an incorrect starting sequence. Possible causes: A) running microswitch failure; B) error in sequence made by the operator; C) incorrect wiring; D) if the default persists, replace the logic.
12) 13) 14) 15) 16) 17) Possible causes: A) the potentiometer is not correctly calibrated; B) the potentiometer is defective. STBY I HIGH Test carried out in standby. Check if the current is 0. If not verified, an alarm is signalled which inhibits machine operations. Possible causes: A) current sensor failure; B) logic failure: first replace the logic; if the defect persists, replace the power unit. SEAT KO This alarm is present in combi systems (traction + pump).
18) MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens digital sensor or if the analog signal 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) 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, check the connection of the sensors.
12 RECOMMENDED SPARE PARTS FOR INVERTER Part number Description C16507 C16505 C16520 C29523 Protected 500 A strip Fuse. Protected 355 A strip Fuse.
13 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of the Contactors’ moving and fixed contacts. Electrical Contacts should be checked every 3 months. Check the 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.
