ZAPI AC3-AC4 Manual.pdf
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ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel +39 0522 960050 – Fax +39 0522 960259
e-mail: zapi@zapispa.it – web: www.zapispa.it
EN
User Manual
AC-3 FLASH
AC-4 FLASH
INVERTER
Copyright © 1975-2011 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.
is a registered trademark property of Zapi S.p.A.
NOTES LEGEND
4
U
The symbol aboard is used inside this publication to indicate an annotation or a
suggestion you should pay attention.
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 - 2/89
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
Contents
1
2
INTRODUCTION ...................................................................................................................6
SPECIFICATION ...................................................................................................................7
2.1
AC-3 FLASH technical specifications .........................................................................7
2.2
AC-4 FLASH technical specifications .........................................................................7
2.3
Block diagram .............................................................................................................8
SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT.......9
3.1
Main contactor ............................................................................................................9
3.2
Microswitches .............................................................................................................9
3.3
Accelerator unit...........................................................................................................9
3.4
Other analog control devices ....................................................................................10
3.5
Speed feedback........................................................................................................11
INSTALLATION HINTS.......................................................................................................12
4.1
Wires and fuses ........................................................................................................12
4.1.1
Connection cables ......................................................................................12
4.1.2
Fuse for I/O circuits.....................................................................................12
4.1.3
Fuse for power section................................................................................12
4.2
Installation of the hardware.......................................................................................13
4.2.1
Positioning and cooling of the controller .....................................................13
4.2.2
Connection of power cables........................................................................13
4.2.3
CAN connections and possible interferences .............................................14
4.2.4
I/O connections ...........................................................................................16
4.2.5
Connection of the encoder..........................................................................16
4.2.6
Main contactor and key connection ............................................................17
4.2.7
Insulation of truck frame..............................................................................18
4.3
Hardware protection and safety features..................................................................18
4.3.1
Protection features......................................................................................18
4.3.2
Safety Features...........................................................................................19
4.4
EMC..........................................................................................................................20
4.5
Various suggestions .................................................................................................21
OPERATIONAL FEATURES ..............................................................................................22
5.1
Diagnosis ..................................................................................................................22
DESCRIPTION OF CONNECTORS....................................................................................24
6.1
Connectors of the logic - Traction configuration .......................................................24
6.1.1
Ampseal and Molex Spox connectors.........................................................24
6.1.2
Amp Saab 42 poles connector....................................................................26
6.1.3
Molex Minifit connectors .............................................................................28
6.2
Connectors of the logic - Pump configuration...........................................................30
6.2.1
Ampseal and Molex Spox connectors.........................................................30
6.2.2
Amp Saab 42 poles connector....................................................................31
6.2.3
Molex Minifit connectors .............................................................................34
6.3
Description of power connections.............................................................................36
DRAWINGS .........................................................................................................................37
7.1
AC-3 FLASH mechanical drawing ............................................................................37
7.2
AC-4 FLASH mechanical drawing ............................................................................38
7.3
Connection drawing - Traction configuration ............................................................39
7.3.1
Ampseal and Molex Spox connectors.........................................................39
7.3.2
Amp Saab 42 poles connector....................................................................40
Page - 3/89
3
4
5
6
7
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
7.3.3
Molex Minifit connectors ............................................................................. 41
7.4
Connection drawing - Pump configuration................................................................ 42
7.4.1
Ampseal and Molex Spox connectors ........................................................ 42
7.4.2
Amp Saab 42 poles connector ................................................................... 43
7.4.3
Molex Minifit connectors ............................................................................. 44
7.5
Connection drawing - Combi configuration............................................................... 45
7.5.1
Ampseal and Molex Spox connectors ........................................................ 45
7.5.2
Amp Saab 42 poles connector ................................................................... 46
7.5.3
Molex Minifit connectors ............................................................................. 47
8
PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE .................................. 48
8.1
Adjustments via Console .......................................................................................... 48
8.2
Additional programming tools ................................................................................... 48
8.3
Description of Console & Connection....................................................................... 49
8.4
Description of Standard Console Menu.................................................................... 49
8.4.1
Traction configuration ................................................................................. 50
8.4.2
Pump configuration..................................................................................... 51
8.5
Sequence for setting up the parameters .................................................................. 52
8.5.1
Traction....................................................................................................... 52
8.5.2
Pump .......................................................................................................... 52
8.6
OPTION and ADJUSTMENTS configuration............................................................ 53
8.6.1
Traction....................................................................................................... 53
8.6.2
Pump .......................................................................................................... 57
8.7
PARAMETER configuration...................................................................................... 64
8.7.1
Traction....................................................................................................... 64
8.7.2
Pump .......................................................................................................... 65
8.8
TESTER: description of the functions....................................................................... 68
8.8.1
Traction....................................................................................................... 68
8.8.2
Pump .......................................................................................................... 69
9
OTHER FUNCTIONS .......................................................................................................... 72
9.1
Description of Console “SAVE” function................................................................... 72
9.2
Description of Console “RESTORE” function. .......................................................... 73
9.3
Description of “ALARMS” menu ............................................................................... 74
9.4
Description of Console “PROGRAM VACC” function............................................... 75
10 AC-3 / AC-4 FLASH DIAGNOSTIC – ALARM DESCRIPTION.......................................... 77
10.1 Analysis of alarms for Traction controller ................................................................. 77
10.2 Analysis of alarms for Pump controller ..................................................................... 83
11 RECOMMENDED SPARE PARTS FOR INVERTER ......................................................... 88
12 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......................... 89
Page - 4/89
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
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INITIALS
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Publication N°:
ADWZP0DF
Edition:
May 2011
ADWZP0DF - AC3 FLASH / AC4 FLASH INVERTER - User Manual
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