Zapi COMBI AC1 Manuale Utente

ELECTRONIC • OLEODYNAMIC • INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY Tel +39 0522 960050 (r.a.) – Fax +39 052

Page - 10/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 4 PROTECTION FEATURES The AC1 is protected against some controller injuries and

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 11/73 5 U SAFETY AND PROTECTION ZAPI controllers are designed according to the prE

Page - 12/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual separate device and stops the truck distinctly from the Elaboration Unit. This

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 13/73 6 OPERATIONAL FEATURES - Stable speed in every position of the accelerator. -

Page - 14/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 7 INSTALLATION SUGGESTIONS AND PRECAUTIONS Read and respect the following sugge

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 15/73 7.4 Main contactor and key connection - The connection of the main contactor

Page - 16/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 8 INSTALLATION Install the controller with the base-plate on a flat metallic su

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 17/73 8.4 Encoder installation 1) AC1 card is fit for different types of encoder. T

Page - 18/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 9 DESCRIPTION OF THE CONNECTORS Figure 9–1

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 19/73 9.1 Connectors of the logic - Standard version with Encoder Figure 9–2 9.1.1

Page - 2/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Copyright © 1975-2005 Zapi S.p.A. All rights reserved The contents of this publ

Page - 20/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual A18 CPOTB Brake potentiometer wiper. A19 ENC A Encoder Channel A. A20 ENC

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 21/73 9.2 Connectors of the logic - MDI PRC Version with Encoder Figure 9–3 9.2.1

Page - 22/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual A18 CPOTB Proportional electrovalves potentiometer wiper. A19 ENC A Encoder

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 23/73 9.3 Description of power connections View of the power bars: Figure 9–4 -BAT

Page - 24/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 10 DRAWINGS 10.1 Mechanical drawing Figure 10–1

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 25/73 10.2 Connection drawing - Standard version with Encoder Figure 10–2

Page - 26/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 10.3 Connection drawing - MDI-PRC version with Encoder Figure 10–3

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 27/73 11 ONE SHOT INSTALLATION PROCEDURE This section of the manual describes the ba

Page - 28/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 11.1 Sequence for Ac Inverter traction setting This section of the manual descr

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 29/73 Can see also the Figure 12–6 for details on the settings. Programming & Ad

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 3/73 Contents 1 INTRODUCTION ...

Page - 30/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 12 PROGRAMMING &ADJUSTMENTS USING DIGITAL CONSOLE 12.1 Adjustments via con

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 31/73 The section describes the Zapi hand set functions. Numbers inside the triangle

Page - 32/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 12.3.2 MDI PRC Version Figure 12–3

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 33/73 12.4 Function configuration We will describe two configurations depending on

Page - 34/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 12.4.1 Config menu “SET OPTIONS” functions list To enter the CONFIG MENU it is

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 35/73 2) SET INPUT #1 This setting handles the analog input CNA#13. It can be used

Page - 36/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 7) BATTERY CHECK This option specifies the handling of the low battery charge d

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 37/73 - Command input for lifting/lowering proportional valves in MDI-PRC version.

Page - 38/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 14) QUICK INV LOGIC This option specifies the active level for the Belly switch

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 39/73 The CNA#18 potentiometer modulates the current in the proportional valve conne

Page - 4/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 12.4 Function configuration ...

Page - 40/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 12.4.2 Config menu “ADJUSTMENTS” functions list To enter the CONFIG MENU it is

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 41/73 2) SET POT BRK MAX (Standard version only). This setting records the maximum

Page - 42/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual maximum accelerator position but with two different slope (see also Figure 13–2

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 43/73 20) OPTION 04 (MDI-PRC version only). See OPTION 05. 21) OPTION 03 (MDI-PRC v

Page - 44/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 12.4.3 Main menu “PARAMETER CHANGE” functions list To enter the MAIN MENU’ it i

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 45/73 3) INVERS. BRAKING Level 0 to 9. It controls the deceleration ramp when the di

Page - 46/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 15) INCHING SPEED (Standard version only because the inching switches are used

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 47/73 24V: then it is necessary that the MDI-PRC generates an output voltage with a

Page - 48/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 12.4.3.31 Setting table of the “PARAMETER CHANGE” functions The following table

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 49/73 12.4.4 Zapi menu “HARDWARE SETTINGS” functions list Confidential documentation

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 5/73 APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN GRAPHIC AND LAYOUT FF PROJEC

Page - 50/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 6) SLIP VALUE Hz value with two decimal digit. This is the slip between the fre

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 51/73 - OFF GND= When CNB#8 is not connected to a battery (key) voltage (or it is

Page - 52/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual QUICK INVERSION reading becomes ON when the Exclusive Hydro Microswitch switch

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 53/73 - OFF GND = When CNA#15 is not closed to a battery (key) voltage (or it is c

Page - 54/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 13 OTHER FUNCTIONS 13.1 Description of console “SAVE” function The SAVE functi

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 55/73 Press OUT to return to the Opening Zapi Display ' ' ' &apos

Page - 56/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Press ENTER for YES, or OUT for No ' % ' ' ' ' &

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 57/73 Flow Chart showing how to use the PROGRAM VACC function of the Digital Consol

Page - 58/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 13.4 Shortform table of the aux output #1 setting The AUX OUTPUT #1 setting spe

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 59/73 13.5 Description of the throttle regulation This regulation applies a not line

Page - 6/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 1 INTRODUCTION The AC1 SSL SENSORED inverter has been developed for applications

Page - 60/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 13.6 Description of the battery charge detection setting The Battery Charge det

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 61/73 14 AC1 ALARMS LIST The ALARMS logbook in the MAIN MENU’ records the alarms of

Page - 62/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual (e.g. when the pump inrush current makes the battery temporary collapsed). So

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 63/73 - Remedy: Check the handbrake switch and its wiring to CNA#13. The handbrake

Page - 64/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual - A Power failure or a Logic Failure occured in the controller. In this case i

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 65/73 with the potentiometer: if the potentiometer gets disconnected on PPOT or NPOT

Page - 66/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 2) STBY I HIGH MDI-PRC Code = 53 - Cause: This diagnosis is executed on

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 67/73 the Driver of the Elecromechanical Brake is short circuited) and this alarm oc

Page - 68/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual than 400msec. The goal of this diagnosis is to detect a failure of the A/D conv

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 69/73 2) WRONG CONFIG MDI-PRC Code = 1 - Cause: It occurs the first time a contr

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 7/73 2 SPECIFICATION 2.1 Technical specifications Inverter for AC asynchronous 3-pha

Page - 70/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 14.2 MDI-PRC “ALARMS” List When the Controller communicates with the MDI-PRC, t

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 71/73 74: MDI DRV2 SHORT At least one On/Off driver on pin#4 and #6 is shorted 75:

Page - 72/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 15 RECOMMENDED SPARE PARTS Part number Description C29508 SW 180 24V Singl

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 73/73 16 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and c

Page - 8/73 AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The AC1 co

AESZP0BA – AC1 SSL SENSORED - FREE VERSION - User Manual Page - 9/73 3.3 Other analog control unit Input CNA#18 is an analog input, whose typical a