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 © 1975-2005 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 INTRODUCTION ...................................................................................................................6 SPECIFICATION ...................................................................................................................6 2.1 Technical specifications..............................................................................................6 2.2 Block diagram ...............................................................................................
12.4 13 14 15 16 Function configuration ................................................................................................ 6 12.4.1 Config menu “SET OPTIONS” functions list................................................. 6 12.4.2 Config menu “ADJUSTMENTS” functions list .............................................. 6 12.4.3 Main menu “PARAMETER CHANGE” functions list..................................... 6 12.4.4 Zapi menu “HARDWARE SETTINGS” functions list ...............................
APPROVAL SIGNS COMPANY FUNCTION INIZIALS GRAPHIC AND LAYOUT FF PROJECT MANAGER MI TECHNICAL ELECTRONIC MANAGER VISA PP SALES MANAGER VISA PN SIGN Publication N°: AESZP0BA Edition: November 2004 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 5/73
1 INTRODUCTION The AC1 SSL SENSORED inverter has been developed for applications such as electric transpallets, golf car, order pickers, sit on stackers with Asynchronous (AC) traction motors up to 2.5KW. The AC1 SSL SENSORED can be supplied in two versions: 1) Sensored version using an Encoder (Sensor Bearing) in the Motor axle 2) SenseCoils version using special auxiliary windings in the motor. Here the Sensored Version is descripted: it adopts an Encoder integrated in the Ball Bearing (Sensor Bearing).
2 SPECIFICATION 2.1 Technical specifications Inverter for AC asynchronous 3-phase motors Regenerative braking Can-bus interface Digital control using a microcontroller Encoder Interface Voltage: .............................................................................................. 24 – 36 - 48V Maximum current (24V,36V): ...................................................... 250A (RMS) for 2' Maximum current (48V):.............................................................
3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The AC1 controller needs some external parts in order to work. The following devices complete the kit for the AC1 installation. 3.1 Microswitches - The microswitches must have a contact resistance lower than 0.1Ω and a leakage current lower than 100µA. When full load connected, the voltage between the key switch contacts must be lower than 0.1V.
3.3 Other analog control unit Input CNA#18 is an analog input, whose typical application is a proportional command to enable a lifting and a lowering proportional Valves. It is possible to use this input for an alternative function is a proportional braking. It should be in a 3 wire configuration. Potentiometer value should be in the 0.5-10KΩ range. Generally, the load should be in the 1.5mA to 30 mA range. The CPOTB (CNA#18) signal range is from 0 to 10V. 3.
4 PROTECTION FEATURES The AC1 is protected against some controller injuries and mulfunctions. These are: 1) Battery polarity inversion It is necessary to fit a MAIN CONTACTOR to cut off the Battery Positive connection to protect the inverter against reverse battery polarity. 2) Connection Errors All inputs are protected against connection errors. 3) Thermal protection If the chopper temperature exceeds 90°C at 24V or 78°C at 48V, the maximum current is reduced in proportion to the thermal increase.
5 U SAFETY AND PROTECTION ZAPI controllers are designed according to the prEN954-1 specifications for safety related parts of control system and to UNI EN1175-1 norm. The safety of the machine is strongly related to installation; length, layout and screening of electrical connections have to be carefully designed. AC1 inverter electronic implements an hardware safety circuit, which is able to switch off the three phase Power Bridge stopping the machine via HARDWARE, that is bypassing the software control.
separate device and stops the truck distinctly from the Elaboration Unit. This is exactly what the Passive Emergency Cell does. In a system with a single microprocessor technology, the weak point is that just one unit (uC) processes the Inputs and decides alone to keep the motor moving or not. If this elaboration unit (uC) fails it is possible it keeps the motor moving against of the state of the commands.
6 OPERATIONAL FEATURES - 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.
7 INSTALLATION SUGGESTIONS AND PRECAUTIONS Read and respect the following suggestions to avoid problem during installation and in the definitive releasing. 7.1 Thermal consideration - - The heat generated by the power block must be dissipated. For this to be possible the compartment must be ventilated and the heat sink materials ample. The heat sink material and system should be sized on the performance requirement of the machine. Abnormal ambient air temperatures should be considered.
7.4 Main contactor and key connection - The connection of the main contactor can be carried out following the drawing in Figure 7–1. An intrinsic protection is present inside the logic when the voltage on the battery power connection overtakes the battery nominal voltage more than a certain percentage.
8 INSTALLATION Install the controller with the base-plate on a flat metallic surface that is clean and unpainted. Apply a light layer of thermo-conductive grease between the two surfaces to permit better heat dissipation. Ensure that the wiring of the cable terminals and connectors is carried out correctly. 8.1 Connection cables For the auxiliary circuits, use cables at least 0.5mm² section. For power connections to the motor and to the battery, use cables having section of 16 mm² (as a minimum).
8.4 Encoder installation 1) AC1 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. A9 +5V/+12V positive of encoder power supply. A10 GND negative of encoder power supply. A19 A phase A of encoder. A20 B phase B of encoder. 2) Connection of encoder with open collector output; +5V power supply.
9 DESCRIPTION OF THE CONNECTORS Figure 9–1 Page - 18/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual
9.1 Connectors of the logic - Standard version with Encoder Figure 9–2 9.1.1 CNA connector A1 NMC Negative of main contactor coil. A2 PMC Positive of main contactor coil A3 NBRAKE Output for driving the electromechanical brake coil; drives the load to -Batt. Maximum current : 3A. A4 NPC Negative of pump contactor coil. A5 PPC , PEV Positive of pump contactor coil and lowering electrovalve coil. A6 NEV Negative of the lowering electrovalve coil. A7 CAN-L Low level CAN-BUS voltage I/O.
A18 CPOTB Brake potentiometer wiper. A19 ENC A Encoder Channel A. A20 ENC B Encoder Channel B. 9.1.2 CNB connector B1 KEY Connected to the power supply through a microswitch (KEY) with a 6.3-10A fuse in series (this could be mounted on the AC1 cover). B2 CM Common of FW / BW / SR1 / SR2 / TILLER / H&S / BELLY / LIFTING / LOWERING microswitches. This connection supplies a key voltage level. B3 TILLER Tiller request input. Must be connected to the tiller microswitch, active high.
9.2 Connectors of the logic - MDI PRC Version with Encoder Figure 9–3 9.2.1 CNA connector A1 NLC Negative of main contactor coil. A2 PMC Positive of main contactor coil A3 NBRAKE Output for driving the electromechanical brake coil; drives the load to -Batt. Maximum current : 3A. A4 NPC Negative of pump contactor coil. A5 PPC , PEV Positive of pump contactor coil and of the auxiliary output load. A6 NEV Negative of the auxiliary output. A7 CAN-L Low level CAN-BUS voltage I/O.
A18 CPOTB Proportional electrovalves potentiometer wiper. A19 ENC A Encoder Channel A. A20 ENC B Encoder Channel B. 9.2.2 CNB connector B1 KEY Connected to the power supply through a microswitch (KEY) with a 6.3-10A fuse in series (this can be mounted on the AC1 cover). B2 CM Common of FW / BW / LIFT AUX / LOW AUX / TILLER / H&S / BELLY / LIFTING / LOWERING microswitches. This connection supplies a key voltage level. B3 TILLER Tiller request input.
9.3 Description of power connections View of the power bars: Figure 9–4 -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.
10 DRAWINGS 10.
10.
10.
11 ONE SHOT INSTALLATION PROCEDURE This section of the manual describes the basic connection procedure. The truck needs (to move) a minimum I/O dotation that it is mandatory: this minimum dotation is listed in the Steps from 1 to 8 below. Step1 Connect a potentiometer in the range 0.5K to 10Kohms, to modify the wished speed, between CNB#12, CNB#10, CNB#11. Step2 Connect two travel demand switches. The FWD travel demand must be connected between a battery (key) voltage and CNB#6.
11.1 Sequence for Ac Inverter traction setting This section of the manual describes the basic AC1 set-up procedure using the hand-set: When the "Key Switch" is closed, if no alarms or errors are present, the Console Display will be showing the Standard Zapi Opening Display (Home Display). For the setting of your truck, use the procedure below. If you need to reply the same setting on different controller, use the Save and Restore sequence as descripted in the 13.1 and 13.2 paragraphs.
Can see also the Figure 12–6 for details on the settings. Programming & Adjustments using Digital Console.
12 PROGRAMMING &ADJUSTMENTS USING DIGITAL CONSOLE 12.1 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 CNC connector of the inverter. 12.2 Description of console (hand set) & connection Figure 12–1 Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum "Release Number 3.02".
The section describes the Zapi hand set functions. Numbers inside the triangles correspond to the same number on the hand set keybord buttons shown in the Figure 13–1. The orientation of the triangle indicates the way to the next function. 12.3 Description of standard console menu 12.3.
12.3.
12.4 Function configuration We will describe two configurations depending on the MDI-PRC setting (see 12.4.1.15): 1) STANDARD version (MDI-PRC Absent) 2) MDI-PRC version (MDI-PRC Present). In this case the drive control communicates with a MDI-PRC through the CAN BUS. They have different list of settings (the Standard version has a reduced settings list). In the next we refer to a complete settings that is the sum of the settings list of both the above configurations.
12.4.1 Config menu “SET OPTIONS” functions list To enter the CONFIG MENU it is necessary to push in the same time the right side top and left side top buttons. Then roll until the SET OPTION item appears on the hand set display. Push the ENTER button (see Figure 12–4). AC1 ZP 1.00 24V 250A 00000 Opening Zapi Display Push ROLL UP + SET UP simultaneously to enter CONFIG MENU The Display will show : SET MOODEL % ' % ' ' ' CONFIG MENU SET MODEL Press ROLL UP or ROLL DOWN button until SET OPTIONS menu appear.
2) SET INPUT #1 This setting handles the analog input CNA#13. It can be used one of three: - Level 0: CNA#13 is managed as input for an analog motor thermal sensor KTY84-130. - Level 1: CNA#13 is managed as a digital cutback speed input (SR#1). - Level 2: CNA#13 is managed as a digital handbrake input. When Level 1 or 2, this input must be connected to a -Batt voltage in order the selected function is not active; it must be opened to turn the selected function active.
7) BATTERY CHECK This option specifies the handling of the low battery charge detection. It can be set one of three: - Level 0: Nothing happens, the battery charge level is ignored. - Level 1: A BATTERY LOW alarm is raised when the battery level is calculated being less than 10% of the full charge. A BATTERY LOW alarm inhibits the Lifting function. - Level 2: A BATTERY LOW alarm is raised when the battery level is calculated being less than 10% of the full charge.
- Command input for lifting/lowering proportional valves in MDI-PRC version. To turn from the first to the second function is just enough to set PEDAL BRAKING to NONE. This option handles the analog input CNA#18 when used as pedal braking input: - ANALOG: - DIGITAL: - NONE: With this setting is possible to modulate the strenght of the braking when the accelerator is released. The strenght of the braking is proportional to the brake pedal potentiometer connected to this input.
14) QUICK INV LOGIC This option specifies the active level for the Belly switch input (CNB#7) - OPTION#1: The quick inversion is executed when CNB#7 is closed to a KEY voltage. - OPTION#2: The quick inversion is executed when CNB#7 is opened from a KEY voltage. 15) MDI-PRC This option specifies: - PRESENT: The MDI-PRC is connected to the AC1 via the CAN Bus: the handling of the Hydraulics is specified on the TRUCK TYPE setting below.
- 3: The CNA#18 potentiometer modulates the current in the proportional valve connected to the pin#8 of the MDIPRC. This proportional valve is normally closed (oil does not pass-through when de-energized) and directly connected between the pump and the tank: to do a Lifting function the voltage into the Proportional Valve is turned fully On, to direct the oil into the tank before the pump contactor closes.
12.4.2 Config menu “ADJUSTMENTS” functions list To enter the CONFIG MENU it is necessary to push in the same time the right side top and left side top buttons. Then roll until the ADJUSTMENTS item appears on the hand set display. Push the ENTER button (see the Figure 12–5 below). AC1 ZAPI V0.
2) SET POT BRK MAX (Standard version only). This setting 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 paragraph 13.3). This procedure must be carried out only if the PEDAL BRAKING option is programmed as ANALOG. 3) MIN LIFT (MDI-PRC version only). By entering this setting, the SW records the actual value of the CNA#18 potentiometer.
maximum accelerator position but with two different slope (see also Figure 13–2). 13) THROTTLE Y POINT These parameter, togheter with the THROTTLE X POINT, changes the characteristic of the accelerator input curve (see also paragraph 13.5): when the accelerator is de-pressed to X point per cent, the corresponding truck speed is Y point per cent of the Maximum truck speed.
20) OPTION 04 (MDI-PRC version only). See OPTION 05. 21) OPTION 03 (MDI-PRC version only). See OPTION 05. 22) OPTION 02 (MDI-PRC version only). See OPTION 05. 23) OPTION 01 (MDI-PRC version only). See OPTION 05.
12.4.3 Main menu “PARAMETER CHANGE” functions list To enter the MAIN MENU’ it is just necessary to push the ENTER button from the home display in the hand set. AC1 ZP 1.
3) INVERS. BRAKING Level 0 to 9. It controls the deceleration ramp when the direction switch is inverted during travel. At Level 9 the truck brakes abrutly. 4) PEDAL BRAKING Level 0 to 9. It controls the deceleration ramp when the travel request is released and the brake pedal switch is pressed to its maximum. At Level 9 the truck brakes abrutly. 5) SPEED LIMIT BRK Level 0 to 9. It controls the deceleration ramp when the accelerator has turned down but not completely released.
15) INCHING SPEED (Standard version only because the inching switches are used for the Lifting and Lowering switches in the MDI-PRC version). Hz value. It determines the speed when the "Inching function" is active (see 12.4.1.3-4 SET INPUT#2, SET INPUT#3). 16) INCHING TIME (Standard version only because the inching switches are used for the Lifting and Lowering switches in the MDI-PRC version). Level 0 to 9. It determines the during time when the "Inching function" is active.
24V: then it is necessary that the MDI-PRC generates an output voltage with a PWM tecnique never overtaking the 50% Duty Cycle to get the Valve’s voltage less equal than 24V. Through this setting it is possible to take care the voltage on the EVD1 and EVD2 never overcomes the nominal voltage of the valves. 23) VALVE 3 VOLTAGE (MDI-PRC version only). A percentage from 0% to 100%.
12.4.3.31 Setting table of the “PARAMETER CHANGE” functions The following table shows the different values at which the parameters can be set. PARAMETER PROGRAMMED LEVEL UNIT 0 1 2 3 4 5 6 7 8 9 ACCELERATION DELAY (*) Sec. 2.05 3.00 3.05 4.00 4.05 5.00 5.05 6.00 6.05 7.00 RELEASE BRAKING (**) Sec. 5.05 5.00 4.05 4.00 3.05 3.00 2.05 2.00 1.05 1.00 INVERS BRAKING (**) Sec. 5.05 5.00 4.05 4.00 3.05 3.00 2.05 2.00 1.05 1.00 PEDAL BRAKING (**) Sec. 5.05 5.00 4.05 4.00 3.05 3.00 2.05 2.
12.4.4 Zapi menu “HARDWARE SETTINGS” functions list Confidential documentation. 12.4.5 Zapi menu “SPECIAL ADJUSTMENTS” functions list Note: the below set-up description is for skilled persons only: if you aren’t please keep your hands off. To enter this Zapi hidden menu a special procedure is required. Ask, this procedure, directly to a Zapi technician. In the SPECIAL ADJUSTMENTS functions list, there are factory adjusted parameters only. 1) ADJUSTMENT #01 (Factory adjusted). % value.
6) SLIP VALUE Hz value with two decimal digit. This is the slip between the frequency and the speed of the motor (SLIP VALUE = FREQUENCY-ENCODER). 7) COSFI From 0.00 to 1.00. This is a coarse extimation of the Power Factor (cosf between the voltage and the current in the motor. 8) CURRENT RMS Ampere value. Root Mean Square value of the line current in the motor. 9) BATTERY CURRENT Ampere value. This is a coarse calculation (not a measurement) of the battery current. 10) BATTERY CHARGE Percentage value.
- OFF GND= When CNB#8 is not connected to a battery (key) voltage (or it is connected to GND), the Lowering request is not active. 17) FORWARD SWITCH ON/OFF. This is the level of the CNB#6 digital input (Forward Travel demand): - ON +VB = When CNB#6 is closed to a battery (key) voltage, the Forward Travel demand is Active. - OFF GND= When CNB#6 is not connected to a battery (key) voltage (or it is connected to GND), the Forward Travel demand is not active. 18) BACKWARD SWITCH ON/OFF.
QUICK INVERSION reading becomes ON when the Exclusive Hydro Microswitch switch closes and connects the CNB#7 input to a key voltage. 22) CUTBACK SWITCH 2 (Standard version only). ON/OFF. This is the level of the CNA#14 digital input (When the MDI-PRC is not present, and SET INPUT #2 is set PRESENT, this is the Speed Reduction #2 request): - ON GND = When CNA#14 is not closed to a battery (key) voltage (or connected to GND) the SR#2 request is active.
- OFF GND = When CNA#15 is not closed to a battery (key) voltage (or it is connected to GND) the Aux Lowering request is not active.
13 OTHER FUNCTIONS 13.1 Description of console “SAVE” function The SAVE function allows the operator to transmit the Parameter values and Configuration data of the chopper 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 chopper using the RESTORE function. The data that is available via the SAVE function is as follows: - All Parameter Values (PARAMETER CHANGE). - Options (SET. OPTIONS).
Press OUT to return to the Opening Zapi Display ' ' ' ' % ' NOTE: in reality the SAVE and RESTORE function requires the Windows PCConsole. 13.2 Description of console “RESTORE” function The RESTORE PARAM function allows transfer of the Console’s stored data into the memory of the chopper. 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.
Press ENTER for YES, or OUT for No ' % ' ' ' ' ' ' ' ' % ' You can see the items that are being stored in the chopper memory whilst the RESTORE routine is happening STORING ACCELER. DELAY When finished, the Console shows : MAIN MENU RESTORE PARAM. Press OUT to return to the Opening Zapi Display ' ' ' ' % ' NOTE: in reality the SAVE and RESTORE function requires the Windows PCConsole. 13.
Flow Chart showing how to use the PROGRAM VACC function of the Digital Console. Opening Zapi Display AC1 ZAPI V0.0 24V 250A 00000 ' % ' ' ' ' Press ENTER to go into the General menu The Display will show : MAIN MENU PARAMETER CHANGE Press ROLL UP or ROLL DOWN button until PROGRAM VACC the display The Display will show : % ' ' % ' ' MAIN MENU PROGRAM VACC Press ENTER to go into the PROGRAM VACC function The Display will show the minimum and maximum values of potentiometer wiper output.
13.4 Shortform table of the aux output #1 setting The AUX OUTPUT #1 setting specifies the handling of the CNA#3 output and the STOP ON RAMP service (when the encoder is used). This handling is summarized in the table below. AUX OUTPUT STOP ON RAMP A3 OUTPUT BEHAVIOUR ON A SLOPE BRAKE ON -Drives the coil of a electromagnetic brake. "The truck is electrically hold on a slope; when the time set by ""auxiliary time"" parameter is elapsed the brake is applied and the 3-phase bridge is released.
13.5 Description of the throttle regulation This regulation applies a not linear relationship between the position of the accelerator and the speed of the truck. The main goal is to increase the resolution for the speed modulation when the truck is slow moving.
13.6 Description of the battery charge detection setting The Battery Charge detection uses two setting that specify the Full Charge Voltage Level (100%) and the Discharge Voltage Level (10%). These two settings are the ADJUSTMENT#01 and the ADJUSTMENT#02 (see 12.4.2.14 and 12.4.2.15). It is possible to adapt the Battery Charge Detection to your specific battery, by changing the above two settings (e.g.
14 AC1 ALARMS LIST The ALARMS logbook in the MAIN MENU’ records the alarms of the controller. It has a FIFO (First Input First Output) structure that means the oldest alarm is lost when the database is full and a new alarm occurs.
(e.g. when the pump inrush current makes the battery temporary collapsed). So first of all check for your failure mode then contact the Zapi technician to look for a countermeasure. As a matter of fact this alarm may occurs also for a HW failure and, in this case, it is necessary to substituite the Controller. 4) LOGIC FAILURE #2 MDI-PRC Code = 18 - Cause: It occurs when the circuit, to compensate for the dead times of the sine waves, is failed. - Remedy: It is necessary to substituite the Controller.
- Remedy: Check the handbrake switch and its wiring to CNA#13. The handbrake switch must be connected between CAN#13 and GND voltage. When it is closed to GND the handbrake is considered active. A failure in the logic is possible too. In this case it is necessary to substituite the controller. 4) LIFT+LOWER MDI-PRC Code = 90 - Cause: This alarm occurs when both a Lifting request and a Lowering request are active at the same time.
- A Power failure or a Logic Failure occured in the controller. In this case it is necessary to substituite the controller. 2) VMN HIGH - Cause: - Remedy: MDI-PRC Code = 31 Before to switch the main contactor on, the SW turns on sequencely the Bottom side Power Mosfets and expects the phase V voltage falls to GND value. If the phase V remains high level this alarm occurs. Two possibilities: - At least a motor phase is not connected to the controller or broken. - A Power Failure (e.g.
- Remedy: with the potentiometer: if the potentiometer gets disconnected on PPOT or NPOT, no current flow in this sense diode and the voltage on the NPOT connection collapses down. When the NPOT voltage is less than 0.3V this alarm occurs. This alarm occurs also when the NPOT voltage is higher than 2Vdc (to detect also the condition of a broken sense diode). Check the voltage on NPOT (CNB#11) and the potentiometer connections.
2) STBY I HIGH MDI-PRC Code = 53 - Cause: This diagnosis is executed only when the main contactor is opened and asked to be closed (e.g. at key on or when the main contactor is opened and a new motion request turns active). Then the outputs of the Current amplifiers must be in a narrow window close to 2.5Vdc (from 2.26V to 2.74V). Otherwise this STBY I HIGH alarm occurs. - Remedy: If the alarm occurs permanently, it is necessary to substituite the controller. 14.1.
- Remedy: the Driver of the Elecromechanical Brake is short circuited) and this alarm occurs. b) When the feedforward PWM is higher than 70% of the battery voltage, the Actual voltage on the Electromechanical Brake is expected high. If it is lower than 14V it means the Electromechanical Brake always gets the truck Braked (probably the Driver of the Elecromechanical Brake is opened) and this alarm occurs.
- Remedy: than 400msec. The goal of this diagnosis is to detect a failure of the A/D converter or a problem in the code flow that omits the refreshing of the analog signal conversion. If the problem occurs permanently it is necessary to substituite the controller. 14.1.7 Seven Blinks Alarms 1) HIGH TEMPERATURE MDI-PRC Code = 61 - Cause: This alarm occurs when the temperature of the base plate is higher than 90° at 24V or 78° at 48V.
2) WRONG CONFIG MDI-PRC Code = 1 - Cause: It occurs the first time a controller is switched on when the non volatile eeprom memory is not initialized yet. Then it is necessary to specify if the controller is AC0 or AC1 type (see AC TYPE 0 in the hidden hardware setting Zapi menu). If the alarm is present, by switching off the key the AC TYPE 0 setting will be turned automatically On (and the controller is specified to be an AC0).
14.2 MDI-PRC “ALARMS” List When the Controller communicates with the MDI-PRC, the alarm condition is represented on the MDI-PRC in a Numeric form is: Source Device Code and Alarm Code.
74: MDI DRV2 SHORT At least one On/Off driver on pin#4 and #6 is shorted 75: MDI DRV2 OPEN At least one On/Off driver on pin#4 and #6 is opened 89: MDI PEV NOT OK The Positive Supply for the Valves is missing 90: MDI NEVP1 NOT OK At least one Proportional Valve driver on pin#8 and #9 is shorted Example: 02A79 is an INCORRECT START alarm on the AC1.
15 RECOMMENDED SPARE PARTS Page - 72/73 Part number Description C29508 SW 180 24V Single Pole Contactor AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual
16 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 wear and condition of the electromechanical brake. According with the ISO 6292 the electromechanical brake must be able to lock the truck in the worst case in terms of admitted gradient and load. The truck manufacturer has to take care the ISO 6292 is fullfilled with a suited maintenance scheduling.
