Description

ZAPI AC2 Controller fault code

18) MOTOR TEMPERATURE

This warning is signalled if the motor temperature switch opens digital sensor

or if the analog signal overtakes the cut-off level. If it happens when the

motor is cold, check the wiring. If all is OK, replace the logic board.

19) THERMIC SENSOR KO

The range of inverter temperature sensor is always checked and a warning is

signalled if it is out of range.

When this alarm is signalled, check the connection of the sensors.

20) CAN BUS KO

The diagnosis of the CAN-BUS line is present only if the inverter uses this

link (depends on the software version). It is signalled if the inverter does not

receive any message from the CAN-BUS line. First of all, check the wiring. If

it is ok, the problem is on the logic board, which must be replaced.

21) SAFETY

This alarm is signalled when the “SAFETY” input is open. The “SAFETY”

circuit gets active and opens the drivers of LC and EB and stops the

machine. Verify the “SAFETY” input connection.

22) BATTERY LOW

If the “battery check” option is ON, a battery discharge algorithm is carried

out. When the charge level is 10%, this alarm is signalled and the current is

reduced to the half of the programmed level.

23) WRONG SET BATT.

When the key is turned ON, the controller check the battery voltage and

verifies it is within a window around the nominal value. Replace the battery

with a correct battery.

24) WAITING FOR NODE

The controller receives from a remote module via CAN Bus the information

that it isn’t possible to close the LC (the module isn’t ready locked in an alarm

state). Verify the other modules to determinate in which of them there is the problem.

Connection of the encoder

1) AC-2 FLASH 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 +12 V. It can

have different electronic output.

D1 +5V/+12V positive of encoder power supply.

D2 GND negative of encoder power supply.

D3 A phase A of encoder.

D4

A phase A inverted (encoder with differential output).

D5 B phase B of encoder.

D6

B phase B inverted (encoder with differential output).

Main contactor and key connection

– The connection of the main contactor can be carried out following the

drawing in the figure.

– The connection of the battery line switches must be carried out following

ZAPI instructions.

– If a mechanical battery line switch is installed, it is necessary that the key

supply to the inverter is open together with power battery 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 when the voltage on the

battery power connection overtakes 40% more than the battery nominal

voltage or if the key is switched off before the battery power line is

disconnected.

Protection features

The AC-2 FLASH is protected against some controller injuries and malfunctions:

–

Battery polarity inversion

It is necessary to fit a MAIN CONTACTOR to protect the inverter against

reverse battery polarity and for safety reasons.

–

Connection Errors:

All inputs are protected against connection errors.

–

Thermal protection

If the controller temperature exceeds 75 °C, the maximum current is reduced

in proportion to the thermal increase. The temperature can never exceed 100

°C.

–

External agents:

The inverter is protected against dust and the spray of liquid to a degree of

protection meeting IP54.

–

Protection against uncontrolled movements:

The main contactor will not close if:

– The Power unit is not functioning.

– The Logic is 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 position.

–

Low battery charge:

When the battery charge is low, the maximum current is reduced to the half

of the maximum current programmed.

–

Protection against accidental Start up

A precise sequence of operations are 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.

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