Zapi ACE2 User Manual
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Zapi ACE2 User Manual

Zapi ACE2 User Manual

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ELECTRONIC • OLEODYNAMIC • INDUSTRIAL
EQUIPMENTS CONSTRUCTION
Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY
Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259
e-mail: zapi@zapispa.it – web: www.zapispa.it
EN
User Manual
ACE2
INVERTER

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Summary of Contents for Zapi ACE2

  • Page 1 ELECTRONIC • OLEODYNAMIC • INDUSTRIAL EQUIPMENTS CONSTRUCTION Via Parma, 59 – 42028 – POVIGLIO (RE) – ITALY Tel +39 0522 960050 (r.a.) – Fax +39 0522 960259 e-mail: zapi@zapispa.it – web: www.zapispa.it User Manual ACE2 INVERTER...
  • Page 2 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.

  • Page 3: Table Of Contents

    PROGRAMMING & ADJUSTMENTS USING DIGITAL CONSOLE........31 Adjustments via Console ..................31 Description of Console & Connection ...............31 Description of Standard Console Menu ..............32 8.3.1 Traction configuration .................32 8.3.2 Pump configuration ..................33 Function configuration ....................34 AF2ZP0CL - ACE2 - User Manual Page - 3/85...
  • Page 4 10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......85 APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN PROJECT MANAGER TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Publication N°: AF2ZP0CL Edition: July 2009 Page - 4/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 5: Introduction

    3) Sensorless version: using only the phase voltage feedback is implemented the motor speed and torque control with the Zapi patented sensor-less control software. Here the Sensored Version is descripted: it adopts an Encoder integrated in the Ball Bearing (Sensor Bearing).

  • Page 6: Specification

    Digital control based upon a microcontroller Voltage:....................24 - 36 - 48 V Maximum current ACE2 24V/400: ..........400 A (RMS) for 3' Maximum current ACE2 36-48V/350: ........350 A (RMS) for 3' 1 hour current rating ACE2 24V/400:..........200 A (RMS) 1 hour current rating ACE2 36-48V/350: ...........

  • Page 7: Block Diagram

    2.3 Block diagram AF2ZP0CL - ACE2 - User Manual Page - 7/85...

  • Page 8: Specification For The Input Devices Filling Up The Installation Kit

    3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The ACE2 inverter needs some external parts in order to work. The following devices complete the kit for the ACE2 installation. 3.1 Microswitches The microswitches must have a contact resistance lower than 0.1 Ω and a leakage current lower than 100 µA.

  • Page 9: Other Analog Control Unit

    2) Connections A22 (PTHERM) and A23 (NTHERM) are used for a motor thermal sensor. It can be digital (on/off sensor, normally closed) or analog. See also chapter 8.4 for more explanation. AF2ZP0CL - ACE2 - User Manual Page - 9/85...

  • Page 10: Speed Feedback

    B = 64 pulses/rev encoder The encoder resolution is given by the last letter in the following list: A = 32 pulses/rev B = 64 pulses/rev C = 80 pulses/rev D = 128 pulses/rev Page - 10/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 11: Installation Hints

    For Safety reasons, we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow. AF2ZP0CL - ACE2 - User Manual Page - 11/85...

  • Page 12: Installation Of The Hardware

    They must be tightened on controller power posts with a Torque of 13-15 The ACE2 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 Centre.

  • Page 13: Wirings: Can Connections And Possible Interferences

    Wrong Layout: Can Bus Power cables Module Module Module The red lines are can wires. The black boxes are different modules, for example traction controller, pump controller and display connected by canbus. AF2ZP0CL - ACE2 - User Manual Page - 13/85...
  • Page 14 (higher diameter means lower impedance), so in this last example the cable between the minus of the Battery and the common ground point (pointed by the arrow in the image) must be dimensioned taking into Page - 14/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 15: Wirings: I/O Connections

    “description of the connectors”. 4.2.5 Connection of the encoder 1) ACE2 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.

  • Page 16: Main Contactor And Key Connection

    It is necessary to specify in the order the type of encoder used, in terms of power supply, electronic output and n° of pulses for revolution, because the logic unit must be set in the correct way by Zapi. 4.2.6 Main contactor and key connection...

  • Page 17: Protection And Safety Features

    ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions. Furthermore, ZAPI is available to develop new SW or HW solutions to improve the safety of the machine, according to customer requirements.

  • Page 18: Emc

    Special attention must be given to the lengths and the paths of the electric connections and the shields. This situation is beyond ZAPI's control. Zapi can offer assistance and suggestions, based on its years experience, on EMC related items.
  • Page 19 “local earth ground”, absorbing excess charge. So it is strongly suggested to connect to truck frame all the parts of the truck which can be touched by the operator, who is most of the AF2ZP0CL - ACE2 - User Manual Page - 19/85...

  • Page 20: Various Suggestions

    If it is necessary to use two or more control units (traction + lift. for ex.), they must belong to the ZAPIMOS family. During battery charge, disconnect ASYNCHRONOUS from the battery. Page - 20/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 21: Operational Features

    High efficiency of motor and battery due to high frequency commutations. Self diagnosis, the faults can be displayed through the console or Zapi’s MDI/Display. Modification of parameters through the programming console.

  • Page 22: Diagnosis

    Diagnosis is provided in two ways. The digital console can be used, which gives a detailed information about the failure; the failure code is also sent on the Can- Bus. Page - 22/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 23: Description Of The Connectors

    REV input is active. It can be used for a flashing light or acoustic indicator. The maximum current load is 1 A. In case of inductive load it is suggested to use a free-wheeling diode across the load (with cathode AF2ZP0CL - ACE2 - User Manual Page - 23/85...

  • Page 24: Connectors Of The Logic - Pump Configuration

    CAN-T If it is connected with A21 (CAN H) it introduces the 120 Ohm termination resistance between CAN-L and CAN-H. SPEED3 Input for third speed request; it is active when Page - 24/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 25: Description Of Power Connections

    View of the power bars: -BATT Negative of the battery. +BATT Positive of the battery. U; V; W Connection bars of the three motor phases; follow this sequence and the indication on the motor. AF2ZP0CL - ACE2 - User Manual Page - 25/85...

  • Page 26: Drawing

    7 DRAWING 7.1 Mechanical drawing ACE2 Existing others versions (with or without power fuse): With heat sink 200x40x150mm (longitudinal / transversal) Page - 26/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 27: Mechanical Drawing Ace2 Power

    7.2 Mechanical drawing ACE2 Power Existing others versions (with or without power fuse): With heat sink 200x40x185mm (transversal) With heat sink 200x40x200mm (transversal / longitudinal) AF2ZP0CL - ACE2 - User Manual Page - 27/85...

  • Page 28: Connection Drawing - Traction Configuration

    7.3 Connection drawing - Traction configuration Page - 28/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 29: Connection Drawing - Pump Configuration

    7.4 Connection drawing - Pump configuration AF2ZP0CL - ACE2 - User Manual Page - 29/85...

  • Page 30: Connection Drawing - Combi Configuration

    7.5 Connection drawing - Combi configuration Page - 30/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 31: Programming & Adjustments Using Digital Console

    Digital Console. The Console is connected to the “B” connector of the inverter. 8.2 Description of Console & Connection Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA, minimum "Release Number 3.02". AF2ZP0CL - ACE2 - User Manual Page - 31/85...

  • Page 32: Description Of Standard Console Menu

    8.3 Description of Standard Console Menu 8.3.1 Traction configuration Page - 32/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 33: Pump Configuration

    8.3.2 Pump configuration AF2ZP0CL - ACE2 - User Manual Page - 33/85...

  • Page 34: Function Configuration

    (truck electrically hold on a ramp) is managed for a time established by "auxiliary time" parameter. After this time, the behaviour depends on the "aux output #1" option programming (see also the following table). Page - 34/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 35 (see chapter 9.4). This procedure must be carried out only if the "Pedal braking" option is programmed as "Analog". 3) SET BATTERY TYPE It selects the nominal battery voltage. 4) ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller. AF2ZP0CL - ACE2 - User Manual Page - 35/85...
  • Page 36 11) LOAD HM FROM MDI When set On, the HourMeter of the Controller is transferred and recorded on the HourMeter of the Standard MDI (connected on the Serial Link). Page - 36/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 37 The Ebrake will be closed with 70% of battery voltage applied to the coil and then the voltage will be kept at the same value. Example 3 MAIN CONT VOLTAGE = 70% AF2ZP0CL - ACE2 - User Manual Page - 37/85...
  • Page 38 HYDRO a slope, but comes down very -The hydraulic steering function slowly till the flat is reached. request is also sent to the pump inverter by the can-bus link. Page - 38/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 39: Pump

    Using the config menu of the programming console, the user can configure the following functions. SUBMENU "SET OPTIONS" 1) DISPLAY TYPE This parameter decides wich display is connected to the inverter. 0: No Display 1: MDI PRC connected 2: ECO DISPLAY connected AF2ZP0CL - ACE2 - User Manual Page - 39/85...
  • Page 40 A23 inputs (the curve can be customized on a customer request). DIGITAL: a digital (ON/OFF) motor thermal sensor is connected between A22 and A23 inputs. NONE: no motor thermal sensor switch is connected. Page - 40/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 41 6) BATT. MIN. ADJ. It adjusts the lower level of the battery discharge table. It is used to calibrate the discharge algorithm with the battery of the application. See chapter 9.5 for more information. AF2ZP0CL - ACE2 - User Manual Page - 41/85...
  • Page 42 The contactor will be closed with 70% of battery voltage applied to the coil and then the voltage will be kept at the same value. Example 3 MAIN CONT VOLTAGE = 70% MAIN CONT V RID = 70% Page - 42/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 43 MAIN CONT V RID = 70% The load will be closed with 70% of battery voltage applied to the coil and then the voltage will be reduced to 49% of battery voltage. AF2ZP0CL - ACE2 - User Manual Page - 43/85...
  • Page 44 ON Main contactor in stand alone config OPTION#1 Traction +pump 1 only MC OPTION#2 Traction +pump 2 10) AUX OUT FUNCTION ON/OFF. If OFF, A18 is not drived and without diagnosis. Page - 44/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 45 OUT if you do not accept the changes. CONFIG MENU 15) SET OPTIONS Menu appears. SET OPTIONS 16) Press OUT again. Display now show the ' ' ' ' % ' Opening Zapi Menu. AF2ZP0CL - ACE2 - User Manual Page - 45/85...
  • Page 46 ' ' ' 11) Press OUT. ' % ' ' % ' 12) Press ENTER to confirm. ' ' ' 13) Repeat the same from 5 to 12 points for the other adjustments. Page - 46/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 47 ' ' ' ' ' ' ' % ' OUT if you do not accept the changes. 13) Press OUT. Display now shows the Opening ' ' ' ' % ' Zapi Menu. AF2ZP0CL - ACE2 - User Manual Page - 47/85...
  • Page 48 OUT if you do not accept the changes. CONFIG MENU 15) ADJUSTMENTS Menu appears. ADJUSTMENT 16) Press OUT. Display now show the Opening ' ' ' ' % ' Zapi Menu. Page - 48/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 49: Parameter Regulation

    8.5 Parameter regulation In addition to the input configuration, parameter modification is made directly by ZAPI on customer specifications, or by the customer, making the adjustments using the programming console. 8.5.1 Traction The following parameters can be modified: 1) ACCELERATION 0 It specifies the motor acceleration at 0 Hz.
  • Page 50 100Hz to 0Hz. 15) MAX SPEED FORW It determines the maximum speed in forward direction. 16) MAX SPEED BACK It determines the maximum speed in backward direction. Page - 50/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 51 ACC PROF. FREQ 1 ACC PROF. FREQ 2 ACC PROF. FREQ 3 RELEASE BRAKING (**) Sec. INVERS BRAKING (**) Sec. DECELERATION BRAKING (**) Sec. PEDAL BRAKING (**) Sec. SPEED LIMIT BRAKING (**) Sec. AF2ZP0CL - ACE2 - User Manual Page - 51/85...

  • Page 52: Pump

    It specifies the motor acceleration at ACC PROF. FREQ 3 [Hz]. At level 0 the acceleration is maximum. Increasing the parameter’s level the acceleration decreases. 5) ACC PROF. FREQ 1 In correspondence to this frequency in [Hz] the acceleration is defined by the Page - 52/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 53 It determines the pump maximum speed when an hydraulic steering function request is received via CAN BUS. 14) CUTBACK SPEED 1 Speed reduction when the cutback input is active. 15) FREQUENCY CREEP AF2ZP0CL - ACE2 - User Manual Page - 53/85...
  • Page 54 ACC PROF. FREQ 3 RELEASE BRAKING (**) Sec. MAX SPEED LIFT SPEED COARSE SPEED COARSE SPEED COARSE HYD SPEED FINE CUTBACK SPEED 1 %Max Sp FREQUENCY CREEP MAXIMUM CURRENT % IMAX AUXILIARY TIME Sec. Page - 54/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 55 OUT if you do not wish to accept the changes and ' % ' ' ' ' ' ' ' ' % ' wish to make further modifications to the parameters. MAIN MENU 13) The Display will show: PARAMETER CHANGE AF2ZP0CL - ACE2 - User Manual Page - 55/85...

  • Page 56: Programming Console Functions

    Accelerator range programming: records the minimum and maximum useful accelerator stroke values for both direction of running. See the console manual for a detailed description of function and parameters. Page - 56/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 57: Sequence For Ac Inverter Traction Setting

    8.7 Sequence for Ac Inverter Traction setting When the "Key Switch" is closed, if no alarms or errors are present, the Console Display will be showing the Standard Zapi Opening Display. If the controller is not configured to your requirements, follow the sequence detailed on Chapter 9.2.

  • Page 58: Sequence For Ac Inverter Pump Setting

    8.8 Sequence for Ac Inverter Pump setting When the "Key Switch" is closed, if no alarms or errors are present, the Console Display will be showing the Standard Zapi Opening Display. If the controller is not configured to your requirements, follow the sequence detailed on Chapter 9.2.

  • Page 59: Tester: Description Of The Function

    15) BACKWARD SWITCH The level of the Reverse direction digital entry BW. ON / +VB = active entry of closed switch. OFF / GND = non active entry of open switch. AF2ZP0CL - ACE2 - User Manual Page - 59/85...

  • Page 60: Pump

    The voltage of the lift potentiometer's wiper (CPOT). The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side. 14) LIFT ENABLE Status of the lifting switch. Page - 60/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 61 ON / GND = active entry of speed reduction microswitch. OFF / +VB = non active entry of microswitch. 20) 2ND HOURMETERS This parameter displays the working hour of pump controller. AF2ZP0CL - ACE2 - User Manual Page - 61/85...
  • Page 62 Display. ' ' ' 9) When you have finished, Press OUT. ' % ' FREQUENCY 10) The Display shows: 11) Press OUT again and return to Opening Zapi ' ' ' ' % ' Display. MAIN MENU TESTER Remember it is not possible to make any changes using TESTER.

  • Page 63: Description Of The Console "Save" Function

    ACCEL. DELAY (ECC.) whilst the SAVE routine is happening. MAIN MENU 11) When finished, the Console shows: SAVE PARAM 12) Press OUT to return to the Opening Zapi ' ' ' ' % ' Display. AF2ZP0CL - ACE2 - User Manual...

  • Page 64: Description Of Console "Restore" Function

    10) The Display will ask “ARE YOU SURE?”. ARE YOU SURE? YES=ENTER NO=OUT ' % ' ' ' ' 11) Press ENTER for YES, or OUT for No. ' ' ' ' % ' Page - 64/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 65: Description Of Console "Program Vacc" Function

    ACCELER. DELAY happening. MAIN MENU 13) When finished the Console displays: RESTORE PARAM. 14) Press OUT to return to the Opening Zapi ' ' ' ' % ' Display. 8.12 Description of Console “PROGRAM VACC” function This enables adjustment of the minimum and maximum useful signal level, in either direction.
  • Page 66 14) Press ENTER for yes, or OUT for NO. ' % ' MAIN MENU 15) When finished, the Console shows: PROGRAM VACC 16) Press OUT again to return to the Opening Zapi ' ' ' ' % ' Menu. Page - 66/85...

  • Page 67: Description Of The Battery Charge Detection Setting

    (e.g. if the Battery Discharged Detection occurs when the battery is not totally discharged, it is necessary to reduce the Bat.Min.Adj setting as indicated in the figure below). 48V NOMINAL BATTERY VOLTAGE 24V NOMINAL BATTERY VOLTAGE AF2ZP0CL - ACE2 - User Manual Page - 67/85...

  • Page 68: Description Of "Alarms" Menu

    - When this alarm occurred the first time. - How many hours are elapsed from the first occurrence to now. - How many times it has occurred in said period. Page - 68/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 69: Faults Diagnostic System

    ' % ' ' ' ' 12) Press ENTER for yes, or OUT for NO. ' ' ' ' % ' 13) Press OUT to return to the Opening Zapi ' ' ' ' % ' Display. 8.15 Faults diagnostic system...

  • Page 70: Microcontroller Alarms Overview

    Safety in The safety input is MC is opened, Start-up, stand-by, Key re-cycle open (it is not running MDI code allarm 86 EB is applied, connected to –Batt) Traction/Pump stopped Page - 70/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 71 Traction/Pump range stopped Contactor closed LC contact is stuck MC is not closed Start-up Traction/Pump (command is not MDI code allarm 75 Request activated), EB is applied, Traction/Pump stopped AF2ZP0CL - ACE2 - User Manual Page - 71/85...
  • Page 72 Wrong Ram The program checks MC is opened, EB is Continuous Key re-cycle Memory the contents of main applied, RAM registers and Traction/Pump MDI code allarm 71 find a “dirty value” stopped Page - 72/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 73: Analysis And Troubleshooting Of Alarms Displayed On Console

    If it does not match, then do an “ADJUST BATTERY” function. Replace the battery. 4) CAPACITOR CHARGE Follows the charging capacitor system: AF2ZP0CL - ACE2 - User Manual Page - 73/85...
  • Page 74 Check the CAN#11 input, if it is connected to –Batt and the alarm is generated then there is a fault in the SAFETY IN hardware circuit. Replace the logic board. 9) SAFETY OUT Cause: Page - 74/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 75 Key input signal down-going pulses (below under voltage threshold) due to external loads, like DC/DC converters starting-up, relays or contactor switching, solenoids energizing / de-energizing. Check the connection of power cables to the battery terminal, positive AF2ZP0CL - ACE2 - User Manual Page - 75/85...
  • Page 76 If the problem occurs after closing the LC (the LC closed and then opens back again), check: Motor connections If motor phases windings/cables have leakages towards truck frame If no problem are found on the motors, the problem is inside the controller, replace it. Page - 76/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 77 If the capacitor voltage does decrease by 20% of the key voltage the alarm is generated. Troubleshooting: It is suggested to verify the power contacts of LC; to replace the LC is necessary. AF2ZP0CL - ACE2 - User Manual Page - 77/85...
  • Page 78 In case no failures/problems have been found externally, the problem is in the controller, which has to be replaced. 26) CONTACTOR OPEN Cause: The main contactor coil has been driven by the controller, but the contactor does not close. Page - 78/85 AF2ZP0CL - ACE2 - User Manual...
  • Page 79 The MC coil driver is not able to drive the load. The device itself or its driving circuit is damaged. Troubleshooting: This type of fault is not related to external components; replace the ACE2 logic board. 29) AUX DRIVER OPEN Cause: The EB/AUX coil driver is not able to drive the load.

  • Page 80: Microcontroller Warning Overview

    71 Forward + The travel demands are Traction is stopped Start-up, stand- Traction Backward active in both directions at by, running request the same time MDI code allarm 80 Page - 80/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 81: Analysis And Troubleshooting Of Warnings Displayed On Console

    In this case, it is necessary to replace the controller. AF2ZP0CL - ACE2 - User Manual Page - 81/85...
  • Page 82 The Maximum current gain parameters are at the default values, which means the maximum current adjustment procedure has not been carried out yet. Troubleshooting: Ask the assistance of a Zapi technician to do the correct adjustment procedure of the current gain parameters 9) SENS MOT TEMP KO Cause: The output of the motor thermal sensor is out of range.
  • Page 83 A failure in the logic is possible too. So, when you have verified the travel demand switches are fine working and the wiring is right, it is necessary to replace the ACE-2 logic board. AF2ZP0CL - ACE2 - User Manual Page - 83/85...

  • Page 84: Recommended Spare Parts For Inverter

    Single Pole Contactor C29522 SW 180 48 V Single Pole Contactor C29508 SW 180 24 V Single Pole Contactor C12531 Connector Ampseal 23 pins Female C12372 Connector Molex 8 pins Female Page - 84/85 AF2ZP0CL - ACE2 - User Manual...

  • Page 85: Periodic Maintenance To Be Repeated At Times Indicated

    The installation of this electronic controller should be made according to the diagrams included in this Manual. Any variations or special requirements should be made after consulting a Zapi Agent. The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual.

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