Description

Technical specifications

Inverter for AC asynchronous 3-phase motors

Regenerative braking functions

Can-bus interface

Flash memory (256 Kbytes On-Chip Program Memory)

Digital control based upon a microcontroller

Voltage:……………………………………………………………..24 – 36 – 48 – 72 – 80 – 96 V

Maximum current (24 V, 36 V):………………………………………….. 500 A (RMS) for 3′

Maximum current (36 V, 48 V):………………………………………….. 450 A (RMS) for 3′

Maximum current (72 V, 80 V): (*) ……………………………….. 275/400 A (RMS) for 3′

Maximum current (96 V): ………………………………………………….. 250 A (RMS) for 3′

Booster (all version)……………………..10% of maximum current for some seconds;

Operating frequency: …………………………………………………………………………..8 kHz

External temperature range: …………………………………………………….-30 °C ÷ 40 °C

Maximum inverter temperature (at full power): ………………………………………..75 °C

Note (*) For the 72/80 V voltage battery two versions are available: with

maximum current provided of 275 A and of 400 A.

Analysis of alarms displayed on console

1) WATCH DOG

The test is made in both running and standby. It is a self-diagnosing test

within the logic. If an alarm should occur, replace the logic.

2) EEPROM KO

Fault in the area of memory in which the adjustment parameters are stored;

this alarm inhibits machine operation. If the defect persists when the key is

switched OFF and ON again, replace the logic. If the alarm disappears,

remember that the parameters stored previously have been cancelled and

replaced by the default values.

3) LOGIC FAILURE #1

This alarm signals that an undervoltage / overvoltage protection operation

has occurred. Two possible reasons:

1. A) A real undervoltage / overvoltage situation happened.
2. B) Fault in the hardware section of the logic board which manages the

overvoltage protection. Replace the logic card.

4) LOGIC FAILURE #2

Fault in the hardware section of the logic board which manages the phase’ s

voltage feedback. Replace the logic board.

5) LOGIC FAILURE #3

Fault in the hardware section of the logic board which manages the hardware

current protection. Replace the logic board.

6) CHECK UP NEEDED

This is a warning. It is an information for the user that the programmed time

for maintenance is elapsed.

7) INCORRECT START

This alarm signals an incorrect starting sequence. Possible causes:

1. A) running microswitch failure;
2. B) error in sequence made by the operator;
3. C) incorrect wiring;
4. D) if the default persists, replace the logic.

8) FORW + BACK

The test is carried out continuously. An alarm is signalled when a double

running request is made simultaneously. Possible causes:

1. A) defective wiring;
2. B) running microswitch failure;
3. C) incorrect operation;
4. D) if the defect persists, replace the logic.

9) HANDBRAKE

The truck does not start because the handbrake switch is opened. Possible

causes:

1. A) defective wiring;
2. B) failure of the microswitch;
3. C) incorrect operation of the operator;
4. D) if the defect persist, replace the logic.

10) ENCODER ERROR

Two consecutive readings of the encoder speed are too much different in

between: because of the inertia of the system it is not possible the encoder

changes its speed a lot in a short period. Probably an encoder failure has

occurred (e.g. one or two channels of the encoder are corrupted or

disconnected). Check both the electric and the mechanical encoder

functionality. Also the electromagnetic noise on the sensor bearing can be a

cause for the alarm.

11) CAPACITOR CHARGE

Follows the charging capacitor system:

When the key is switched ON, the inverter tries to charge the capacitor

through a power resistance, and check if the capacitor are charged within a

timeout. If this is not true: an alarm is signalled; the main contactor is not

closed.

Possible reasons:

1. A) the charging resistance is opened; if it is opened.
2. B) The charging circuit has a failure.
3. C) There is a problem on the power modules.

12) VMN LOW, VMN HIGH

The test is carried out during initial diagnosis and in standby.

Possible causes:

1. A) problem with the motor connections or the motor power circuit; check if

the 3 phases are correctly connected; check if there’s a dispersion of the

motor towards ground;

1. B) inverter failure, replace it.

13) VACC NOT OK

The test is made in standby. This alarm indicates that the accelerator voltage

is 1 V greater than the minimum value programmed by the PROGRAM

VACC function.

Possible causes:

1. A) the potentiometer is not correctly calibrated;
2. B) the potentiometer is defective.

14) PEDAL WIRE KO

This alarm is signalled if a fault is detected in the accelerator unit wiring

(NPOT or PPOT cable is interrupted).

15) PEDAL FAILURE

This alarm can be activated on request and it is signalled if the accelerator

signal is out of the range. Possible cause: an hardware problem on the logic

board or a potentiometer problem (disconnected wire, damaged cursor).

16) STBY I HIGH

Test carried out in standby. Check if the current is 0. If not verified, an alarm

is signalled which inhibits machine operations. Possible causes:

1. A) current sensor failure;
2. B) logic failure: first replace the logic; if the defect persists, replace the

power unit.

17) DATA ACQUISITION

This alarm is signalled in the current gain acquisition phase. Wait the end of

the acquisition activity.

18) MAIN CONTACTOR ALARMS

–

COIL SHORTED

When the key is switched ON the µP checks the MC driver FF SR. If it

does not react in a correct way to the µP stimulus, the alarm is signalled.

Replace the logic board. The FF SR makes an hardware control of the

current in the MC coil. If this is too high, it opens the MC and the alarm is

signalled.

Check if there are external shortcircuit and if the ohmic value of the MC is

correct; otherwise replace the logic.

–

DRIVER SHORTED

When the key is switched ON, the µP checks that the MC coil driver is

not shorted; if it is, this alarm is signalled; replace the logic board.

–

CONTACTOR DRIVER

When the initial diagnosis is finished, the traction logic closes the MC and

checks the voltage on the Drain of the driver. If this is not low, an alarm is

signalled.

Replace the logic.

–

CONTACTOR OPEN

The main contactor coil has been driven by the logic board, but the

contactor does not close. Two possible reasons:

1. A) the wires to the coil are interrupted or not well connected.
2. B) the contact of the contactor is not properly working.
3. –CONTACTOR CLOSED The controller checks if the LC contact is closed when the coil isn’tdriven, trying to discharge the capacitor bank. If they don’t discharge, thefault condition is entered. It is suggested to check the contactor contact, if

   it is mechanically stuck or pasted.

   19) AUX OUTPUT KO

   The µP checks the driver of the electromechanical brake. If the status of the

   driver output does not correspond to the signal coming from the µP, the

   alarm is signalled. Replace the logic.

   20) HIGH TEMPERATURE

   Inverter temperature is greater than 75 °C. The maximum current is reduced

   proportionally to the temperature increase. The inverter stops at 100 °C.

   If the alarm is signalled when the inverter is cold:

   1. A) check the wiring of the thermal sensor;
   2. B) thermal sensor failure;
   3. C) logic failure.

   21) 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.

   22) 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.

   23) MOT. TH. SENSOR KO

   The range of motor 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.

   24) 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.

   25) 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.

   26) SAFETY KO

   This alarm is present in combi systems (traction + pump). If a stopping alarm

   is detected on the pump, the traction also stops. The failure must be looked

   for in the pump inverter.

   27) 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.

   28) 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.

   29) 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.

   AC-2 FLASH INVERTER DIAGNOSTIC –

   TRACTION CONFIGURATION

   The alarms are signalled by a diagnostic LED.

   1 blink: logic failure (“WATCHDOG”, “EEPROM KO”, “LOGIC

   FAILURE #1”, “LOGIC FAILURE #2”, “LOGIC

   FAILURE #3”, “CHECK UP NEEDED”).

   2 blinks: running request on start-up or error in seat sequence,

   double direction request or encoder problem

   (“INCORRECT START”, “HANDBRAKE”, “FORW +

   BACK”, “ENCODER ERROR”).

   3 blinks: phase voltage or capacitor charge failure

   (“CAPACITOR CHARGE”, “VMN LOW”, “VMN HIGH”).

   4 blinks: failure in accelerator (“VACC NOT OK”, “PEDAL WIRE

   KO”, “PEDAL FAILURE”).

   5 blinks: failure of current sensor (“STBY I HIGH”, “DATA

   ACQUISITION”).

   6 blinks: failure of contactor driver (“COIL SHORTED”,

   “DRIVER SHORTED”, “CONTACTOR DRIVER”, “AUX

   OUTPUT KO”, “CONTACTOR OPEN”, “CONTACTOR

   CLOSED”).

   7 blinks: excessive temperature (“HIGH TEMPERATURE”,

   “MOTOR TEMPERATURE”, “THERMIC SENSOR

   KO”, “MOT. TH. SENSOR KO”).

   8 blinks: failure of can-bus or problem in the SAFETY circuit

   (“CAN-BUS KO”, “SAFETY”, “SAFETY KO”).

   long blink: discharge battery or wrong battery voltage (“LOW

   BATTERY”, “WRONG SET BATT.”).

   no blink: problem in a remote module (“WAITING FOR NODE”).

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