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    173 views39 pages

    ZAPI AC3 Flash Inverter

    Uploaded by

    Christian Bedoya

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
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    Electrical System Lea Electrical System ZAP! AC3 Flash Inverter IssueB- 40772013 Part Number: 42414:00 Section L L-2 This Page is intentionally Left Blank Issue B— 40712013 Part Number: 4241400 Electrical System Le 3 Contents Introduction. Specification Technical Specification, Block Diagram Specification for the Input Devices Filing Up the installation Kit Microswitcnas. ‘Accelerator Unit Speed Feedback Installation Hints Material Overview. Contactors. Fuses Inctallation of the Haraware. Positioning and Cooling of the Controller Wirings: Power Cables. Wirings: YO Connections Main Contactor and Key Connection Insulation of Truck Frame Protection and Safety Features. Protection Features. Battery Polarity Inversion Connection Errors Thermal Protection, External Agents. Protection Against Uncontrolled Movements Low Battery Charge Protection Against Accidental Start-up Operational Features: 7 Diagnosis Description of Connectors Connectors of the Logie Traction Configuration. Molex Minit Connectors. Description of Power Connections Drawings ‘Mechanical Drawing ‘Molex Minifit Connectors. Programming and Adjustments Using the Digital Console. ‘Adjustments via Console. ‘Description of the Console and Connection Description of Standard Console Menu Function Configuration Flow chart showing how fo make changes to OPTION Menu. Flow chart showing how to make changes to ADJUSTMENT Menu, Flow chart showing how to use the SET BATTERY TYPE adjustment Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console, BREBRaaaasaaS Parameter Regulation... 24 Flow Chart showing how to make Programme changes using Digital Console fited with Eprom CK ULTRA, 26 Programming Console Functions 28 ‘Sequence for AC Inverter Traction Setting 28 Tester: Descripion of the Functions ar Flow Chart showing how to use the TESTER function of the Digital Console, 29 Other Functions 29 Description of the Console "SAVE" Function 29 Flow Chart snowing how to use the SAVE function ofthe Digital Console 30 ‘Description of the Console "RESTORE" Function 30 Flow Chart showing how to use the RESTORE function ofthe Digital Console, at Issue B - 4/07/2013 Part Number: 42414-00 Section L Le 4 Description of Alarms Menu : 3 Flow Chart showing how to use the ALARWS function via the Digital Console, 2 Description of the Console "PROGRAM VACC” Function 32 Flow Chart showing how to use the PROGRAM VACC function ofthe Digital Console. 33 ‘AC-3 Traction Flash Diagnostic. Error! Bookmark not defined. ‘Analysis of Alarms Displayed on Console. ns se ssn dA Recommended Spare Parts for Inverter ae 38 Periocic Maintenance to be Repeated at Times indicated " somone SB Issue B ~ 410772013 Part Number: 42444-00, Electrical System a (aes: Part Number: 42414-00 iseue 8 - 4/07/2013 Section L L. 8 Introduction Maximum inverter temperature (at fll power) = Within the ZAPIMOS family, the AC-3_ FLASH 75°C inverter is the model suitable for control of 712 kW ‘motors. it has been expressly designed for battery elect traction. Block Diagram {ts ft for electric truck, electric cars, tractors and 2 buses. 5 r aid ~. +8 2 5 | a | 1 4+ Fae I + — Specification +--+ Technical Specification ; : ~ Inverter for AC asynchronous 3-phase motors iz 919071 TosLNa3 — Regenerative braking functions T = Can-bus interface Tall Flash memory (256 Kbytes On-Chip Program | |e EH Esl]. Memory) Digital control based upon a BYE] 2) / S318 microcontroller | TELE ES ~ Voltage = -48- 72-80-96 V Figure 12 — Maximum current (36 V, 48 V) = 600 A (RMS) for 3" — Maximum current (72 V, 80 V) = 600 A (RMS) for 3 Maximum current (98 V) for! 450 A (RMS) ~ Booster (al versions) = 10% of maximum current for some seconds = Operating frequency = 8 kHz ~ External temperature range = -30 °C to 40°C. Issue B - 4/07/2013 Part Number: 42414-00 Electrical System Ler Specification for the Input ? > Devices Filling Up the Installation jeu ae ie ae 8a 88 The AC-3 FLASH inveters need some exemal go be BR paris. in order to work. The following devices o. se oF omplete the Kt forthe AC-S FLASH insaiaion patieeecnete keg Microswitches i ea &3 The miswoswiiches must have @ contact gee ee eee resistanoe lower than 0.1 ohm and a leakage YOS OF OF current lower than 100 yA. g Ye 5 & = When full oad connected, the votiage drop 4 between the key switch contacts must be x lower than 0.V 3 a +The microswitches send a vollage signal to the microprocessor when a function request ” is made (for .g. a running request) Figure 13 Accelerator Unit ‘The accelerator unit can consist of @ potentiometer a > or a Hall effect device. It should be In a S-wire 2 i. configuration 2g ee POT (A16 Ampseal connector version, A1t Amp a fe Seab 29 poles connector version; A15 Amp Saab ae = 42 poles connector version; At Molex Minit cig 32 version) signal ranges from Oto 10 V. as) 7 Patenllometer value should be inthe 0 ~ 10 KO oie ks ‘ange; generally, the load should be in the 1.5 mA ge 28 a to 30 mA range. Faults can occur itis outside this ge. fe oe ne fee £ 8 & ‘Tho Procedure for automatic potentiometer signal ie acquisition is carried out using the Console. This 7 enables adjustment ofthe minimum and maximum ce useful signal lavel (PROGRAM VACC function), in. = either ditection, This function is unique when iis i necessary to compensate for asymmetry with the 4 ‘mochanical elements associated with the a Dotentometer, especialy relating to the minimum z level. The sequence of procedure is described in = the programming console manual el Figure La Issue 8 - 4/07/2013 Part Number: 42414-00 Section L ‘The graphs L5 & L6 show the output voltage from a ‘non-callprated potentiometer with respect to the ‘mechanical "zero" of the control lever, Ml and MA indicate the point where the diction switches close. 0 represents the mechanical zero of the rotation. LS shows the relationship of the motor voltage without signal acquisition being made. L6 shows the same relationship after signal acquisition of the potentiometer. A205 Toe 100 Tes MECHANICAL ANGLE Figure 16 Speed Feedback ‘The motor control is based upon the motor speed feedback. The speed transduoer is an incremental ‘encoder, with two phases shifted at 90°. The ‘encoder can be of different types: ~ power supply: +5 Vor+12V = electric output: open collector (NPN or PNP), push-pull, line diver + slandard (A and B) or differential (A, A,B, B) output Issue 8 - 4/07/0013 Note: The encoder resolution and the motor poles pair (the controller can handle), is specified In the home page cisplay of the handset showing following headline AcsT2c =F CNRIO7 ‘The definitions of which are as follows: ACST = AC-3 traction controller 2.= moto’s poles pair number C= 80 pulsesirev encoder F=ftash ‘CNR1.07 = software version number Installation Hints In the description of these installation suggestions you will find; + Information, useful for anyone who is working on the installation, or a deeper examination of the content = Warnings, describing operations that can lead to a failute of the electronic device, can be dangerous / harmful for the operator or are important to guarantee system performance and safety, Material Overview Prior to the start of the instalation itis necessary ‘to have the required materials. The weong choice of cables oF otter parts could lead to failures, misbehaviou: andior poor performance. Contactors “The main contactor must be instal Depending on the position of a jumper installed in the logic board The oulput which drives the main contactor coil is on/off (the coll is driven with the full battery voltage), The output which drives the main contactor coilis switched at high frequency (1 kHz) with a duty cycle of 70%; this feature is useful to Part Number: 42414-00 Electrical System Le decrease the power dissipation of the ‘contactor coil Fuses Use a 6.3A Fuse for protection of the auxiliary circuits For protection of the power unit, refer to diagrams. The Fuse value shown is the maximum allowable. For special applications or requirements these values can be reduced. For Safety reasons, we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow. Installation of the Hardware Before performing any operations, ensure thal the battery is disconnected. When the installation is ‘complete, start the machine with the drive wheels. raised from the floor to ensure that any potential installation errors do not compromise safety ‘After operation, even with the Key Switch open, the internal capacitors may remain charged for some time. For safe operation, we recommend that the battery is disconnected, and a short circuit 's made between Batlery Posilive and Battery Negative power terminals of the inverter using a Resistor between 10 ohm and 100 ohm Positioning and Cooling of the Controller Install the inverter with the base-piate on a flat metalic surface that is clean and unpainted Apply a light layer of thermo-conduetive grease between the two surfaces to permit better heat dissipation. Ensure that the witing of the cable terminals and connectorsis carried out correctly. Fit transient suppression devices to the hom, solenoid valves, and contactors not connected to the controler The heat generated by the power block must be dissipated. For this to be possible the ‘compartment must be ventilated and the heat sink material ample. ‘The heat sink material and system should be sized on the performance requirement of the machine. Abnormal ambient ait temperatures should be considered. In situations where ventiation is poor or heat exchange is dificult, forced air ventilation should be used. Issue B= 4/07/2013 The thermal energy dissipated by the power block ‘module varies and is dependent on the current drawn and the duty cycte. Wirings: Power Cables The power cables must be as short as possible to minimize power losses. They must be tightened fon controller power posts with a Torque of 13 16Nm: The AC-3 FLASH module should only be connected to a traction battery. Do not use converters, outputs or power supplies. For special applications please contact the nearest Zapi Service Cente. Monten Do not connect the controller to a battory with @ nominal voltage different than the value indicated on the controller label. A higher battery voltage may cause power section failure, A lower voltage may prevent the logic operating. Wirings: VO Connections ‘Aftor crimping the cable, very that ll strands are entrapped inthe wire barrel \Vorify that all the crmped contacts are completely Inserted in the connector cavities. Monin ‘A.cable connected to the wrong pin can lead to short circuits and failure; before turning on the truck for the first time, verify with a multimeter the continuity between the starting point and the end of a signal wire, For information about mating connector pins, see “Description of Connectors", page Ltt Main Contactor and Key Connection ‘The connecton of the baltery ine switches must be carried out following ZAP! instructions. If a mechanical battery line switch is installed, iis necessary that the key supply to the inverter is ‘open together with power batiery line; if not, the inverter may be damaged if the switch is opened during a regenerative braking, ‘An intrinsic protection is present inside the logic Part Number: 42414-00 Section L L- 10 \when the voltage on the battery power connection ‘overtakes 40% more than the baltery nominat voltage or if the Key is switched off before the battery power line is disconnected. Insulation of Truck Frame Mourton Tho truck frame must be isolated from all electrical potential of the truck power line, in accordance with EN-1175 “Safety of machinery ~ Industrial truck", chapter 5.7 Protection and Safety Features Protection Features The AC-3 FLASH is protected against some controller injuries and malfunctions: Battory Polatity Inversion It ig necessary to fit a MAIN CONTACTOR to protect the inverter against reverse battery polarty and for safely reasons. Connection Errors ‘All inputs are protected against connection errors. ‘Thermal Protection It the controller temperature exceeds 75 °C, the maximum current is reduced in proportion to the thermal increase, The temperature can never exceed 100°C. Extomal Agents The inverter is protected against dust and the spray of quid to a degree of protection meeting IP54 (Molex Minift connectors), IP65 (Ampseal and Amp Saab connectors). Protection Against Uncontrolled Movements “The main contactor wil not close if ~The Power uni s not functioning. The Logic ie not functioning perfectly = The output voltage of the accelerator does not fall below the minimum voltage value stored, with 1 V added Running microswitch in closed postion Low Battery Charge When the battery charge Is low, the maximum current is reduced to half of the maximum current programmes. issue 8 — 4/07/2013, Protection Against Accidental Start-up A precise sequence of operations is necessary before the machine will start (Operation cannot begin if these operations are not carried out correctly. Requests for drive must be made after closing the key switch. Operational Features + Speed control = Optimum behaviour on a slope due to the ‘speed feedback: Regenerative braking when the accelerator pedal is partially released (deceleration). + The motor speed follows the accelerator, starting regenerative braking if the speed overtakes the speed setpoint = Stable speed in every position of the accelerator. Regenerative release braking based upon deceleration ramps. = Direction inversion with regenerative braking based upon deceleration ramp. Regenerative braking and direction inversion without contaciors: only the main contactor is. ‘present = The release braking ramp can be modulated by an analegue input, so that a proportional brake feature is obtained. (Optimum sensitivity at low speods. Voltage boost at the start and with overload to oblain more torque (with current contre). + High efficiency of motor and battery due to high frequency commutations, - Self diagnosis with indication of the fautt shown by MDI fault codes. Modification of parameters through the programming console ‘Part Number: 4244-00 Electrical System beat Internal hour-meter with values thal can be displayed on the console Memory of the last five alarms with relative hhour-meter and temperature displayed on the conso'e, + Test function within console for checking ‘main parameters. Diagnosis The microcontroller continually monitors the Inverter and carries out a diagnostic procedure on the main functions, The diagnosis is made in 4 points: 41. Diagnosis on key switch closing that checks: watchdog circull, current sensor, capacitor charging, phase's voltages, contactor drives, ccan-bus Interface, thal the switch sequence for operation is correct and that the output of accelerator unit is correct 2 Standby diagnosis in stby that checks: walchdog circuit, phase’s voltages, contactor driver, current sensor and can-bus interface. 3. Diagnosis during operation that checks: watchdog circults, contactor driver, current sensors and can-bus interface 4. Continuous diagnosis thal chacks: temperature of the inverter, motor temperature. Diagnosis is provided in two ways. The digital console can be used, which gives detailed information about the failure; the falure code Is also displayed on the MOI. Description of Connectors Connectors of the Logic Traction Configuration The AC-3 FLASH has been designed to be ‘produced with six Molex Minfit connectors, Molex Minifit Connectors. At cor ‘Accoletaior potentiometer wiper a2 POT Potentometer positive: 10 V output keep load> 1 kO, a3 NPOT Nogatve of accelerator unit, tested for wie disconnacton Glagnosis, a OM Common of FW} BW I BACK FW / BACK, BW / EXCLUSIVE HYDRO J ENABLE microswitches. AS FORW = Forward direction _requost Int. It must be. connected othe forward direction rmicroswitch, activ high aS BW Backward directon request Input It must be connected 1 the backwaré rection ricroswich, active high Ay PB Brake request input It must be connected 10 the brake pedal switch, active high 2 CPOTB —_—Bake potentiometer wiper. ‘9 PPOTB —_—Brake potentiometer positive 40 V output; keep load > 1 Ka Alo NPOTB Balt. Al Bart Batt lz BACK, Inching funeton, forward FORW direction input. I! must be ‘connected to the inching forward switch, Active high, AIS BACK, Inching functon, backward BACK direction input it must be ‘connected to the inching ‘backward switch. Activa high Ald EX HYDRO Exclusive hydro or TENABLE accelerator enable uncion input I must be connected 0 the exclusive hydro miroswitch or tthe Sccolerator enable switch. ‘Aclve high (see also ‘OPTION chapten, Connecied to the power ‘supply through a microswiteh (CH) witn 2 63-4 fuse in 1 key 82 Plc Positve of main. contactor Issue B = 4/07/2013 Part Number: 4261400 Section L Le 12 83 PBRAKE = Positve ofthe Fi PCLRXD Positive seria reception, lectromechanicalbrake col F2 —NCLRXD Negative serial reception 84 SEAT SEAT input; must_be connected to the SEAT FS PCLTXO Positive serial transmission. Imitoswate ts active Nigh, Fé NCLTXD Negative seria transmission, 85 SAFETY If not connected to -Batt the FS GND Nagalve console poner MC col power output wil be supply,

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