Zapi AC-2 User Manual Page 1

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

Page - 10/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 4 INSTALLATION HINTS In the description of these installation suggestions you will find som

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 11/72 4.2 Installation of the hardware U Before doing any operation, ensure that the battery is

Page - 12/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual It was invented by the German company Bosch to be used in the car industry to permit commun

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 13/72 connection is the daisy chain. U Correct Layout: Note: Module 1 power > Module 2 pow

Page - 14/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual problems that arise from this complexity - simplified design (readily available, multi sour

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 15/72 4) Connection of encoder with open collector output: +12 V power supply. U VERY IMPORTAN

Page - 16/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 4.3 Protection and safety features 4.3.1 Protection features The AC-2 FLASH is protected a

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 17/72 detects a failure in the "SAFETY" circuit, the microcontroller itself will bring

Page - 18/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 3) The second type of immunity, ESD, concerns the prevention of the effects of electric cu

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 19/72 4.5 Various suggestions - Never connect SCR low frequency chopper with ASYNCHRONOUS INVERT

Page - 2/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual Copyright © 1975-2006 Zapi S.p.A. All rights reserved The contents of this publication is a

Page - 20/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 5 OPERATIONAL FEATURES - Speed control. - Optimum behaviour an a slope due to the speed fe

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 21/72 contactor driver, current sensor, can-bus interface. 3) Diagnosis during operation that che

Page - 22/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 6 DESCRIPTION OF THE CONNECTORS 6.1 Connectors of the logic - Traction configuration A

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 23/72 B2 MODE This input allows the customer to select the software for traction or lifting app

Page - 24/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual be disabled. It can also be used as a general purpose input. F6 PTHERM Input for motor te

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 25/72 6.2 Connectors of the logic - Pump configuration A1 PCLRXD Positive serial reception.

Page - 26/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual Configuration: MODE: Open (not connected) Traction inverter MODE: Close (connected with B1

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 27/72 F9 NHYDRO Output for driving an hydraulic steering contactor; it drives the load to -Batt

Page - 28/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 6.3 Description of power connections View of the power bars: -BATT Negative of the batte

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 29/72 7 DRAWINGS 7.1 Mechanical drawing

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 3/72 Contents 1 INTRODUCTION ...

Page - 30/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 7.2 Connection drawing - Traction configuration

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 31/72 7.3 Connection drawing - Pump configuration

Page - 32/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 7.4 Connection drawing - Combi configuration

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 33/72 8 PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE 8.1 Adjustments via Console Adjustmen

Page - 34/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 8.3 Description of Standard Console Menu 8.3.1 Traction configuration

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 35/72 8.3.2 Pump configuration 8.4 Function configuration 8.4.1 Traction Using the CONFIG MENU o

Page - 36/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual SUBMENU "SET OPTIONS" 1) HOUR COUNTER - RUNNING: the counter registers travel t

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 37/72 9) AUX FUNCTION - ON/OFF: if this option is programmed ON the traction inverter applies m

Page - 38/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 8) ADJUSTMENT #04 This parameter determines the motor temperature level at which the “Motor

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 39/72 AUX OUTPUT STOP ON RAMP F9 OUTPUT BEHAVIOUR ON A SLOPE BRAKE ON -It drives the coi

Page - 4/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 8.5 Parameter regulation...

Page - 40/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual Very important: In the combi system (pump + traction), the battery discharge calculation fo

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 41/72 6) ADJUSTMENT #04 This parameter determines the motor temperature level at which the “Motor

Page - 42/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual Flow chart showing how to make changes to OPTION Menu. 1) Opening Zapi Menu. AC2 ZAPI V

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 43/72 Flow chart showing how to make changes to ADJUSTMENTS Menu. 1) Opening Zapi Menu. AC2 ZA

Page - 44/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual Flow chart showing how to use the SET BATTERY TYPE adjustment. 1) Opening Zapi Menu. AC

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 45/72 Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console. 1) Opening Za

Page - 46/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 8.5 Parameter regulation In addition to the input configuration, parameter modification is

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 47/72 PROGRAMMED LEVEL PARAMETER UNIT 0 1 2 3 4 5 6 7 8 9 ACCELERATION DELAY (*) Sec. 2.5 3.

Page - 48/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 6) 1ST SPEED FINE First speed, fine regulation. 7) 2ND SPEED FINE Second speed, fine reg

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 49/72 Flow Chart showing how to make Programme changes using Digital Console fitted with Eprom CK

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 5/72 1 INTRODUCTION Within the ZAPIMOS family, the AC-2 FLASH inverter is the model suitable for

Page - 50/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual encoder (Hz) encoder (Hz) slip value (Hz) slip value (Hz) current rms (A) current rms (A

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 51/72 If the machine is a forklift, check the performance with and without load. 9) RELEASE BRAK

Page - 52/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual the TESTER function of the console. The Console acts as a multimeter able to read voltage,

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 53/72 - OFF / +VB = non active entry of microswitch. 16) BRAKE SWITCH The level of the Pedal Bra

Page - 54/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual - OFF / GND = non active entry of open switch. 11) 2ND SPEED SWITCH Status of the second s

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 55/72 Flow Chart showing how to use the TESTER function of the Digital Console. 1) Opening Zapi

Page - 56/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 9 OTHER FUNCTIONS 9.1 Description of the Console “SAVE” function The SAVE function allows

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 57/72 12) Press OUT to return to the Opening Zapi Display. ' ' ' ' % '

Page - 58/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 9.2 Description of Console “RESTORE” function The RESTORE PARAM function allows transfer o

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 59/72 12) You can see the items that are being stored in the inverter memory whilst the RESTORE r

Page - 6/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 2 SPECIFICATION 2.1 Technical specifications Inverter for AC asynchronous 3-phase motors Reg

Page - 60/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 9.3 Description of “ALARMS” menu The microprocessor in the inverter remembers the last fiv

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 61/72 9.4 Description of Console “PROGRAM VACC” function This enables adjustment of the minimum

Page - 62/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 8) Press ENTER to clear these values. Display will show 0.0. ' % ' ' &ap

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 63/72 10 AC-2 FLASH INVERTER DIAGNOSTIC - TRACTION CONFIGURATION The alarms are signalled by a di

Page - 64/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 4) LOGIC FAILURE #2 Fault in the hardware section of the logic board which manages the pha

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 65/72 A) the charging resistance is opened; if it is opened. B) The charging circuit has a fail

Page - 66/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual - CONTACTOR CLOSED The controller checks if the LC contact is closed when the coil isn’t d

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 67/72 11 AC-2 FLASH INVERTER DIAGNOSTIC - PUMP CONFIGURATION The alarms are signalled by a diagno

Page - 68/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 4) LOGIC FAILURE #2 Fault in the hardware section of the logic board which manages the pha

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 69/72 Possible causes: A) the potentiometer is not correctly calibrated; B) the potentiometer i

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 7/72 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The AC-2 FLASH inverte

Page - 70/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 18) MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens digit

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 71/72 12 RECOMMENDED SPARE PARTS FOR INVERTER Part number Description C16507 Protected 500 A

Page - 72/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual 13 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED Check the wear and condition of t

Page - 8/72 ADEZP0DC - AC-2 FLASH INVERTER - User Manual The two graphs show the output voltage from a non-calibrated potentiometer with respect to

ADEZP0DC - AC-2 FLASH INVERTER - User Manual Page - 9/72 F = flash The encoder resolution is given by the last letter in the following list: A = 32