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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: [email protected] – web: www.zapispa.it

User Manual

ACE2

INVERTER

Summary of Contents for ACE2

Page 1: ...TRONIC 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 INVER...

Page 2: ...ges 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...

Page 3: ...2 6 Main contactor and key connection 16 4 2 7 Insulation of truck frame 16 4 3 Protection and safety features 17 4 3 1 Protection features 17 4 3 2 Safety Features 17 4 4 EMC 18 4 5 Various suggestio...

Page 4: ...Console PROGRAM VACC function 65 8 13 Description of the battery charge detection setting 67 8 14 Description of ALARMS menu 68 8 15 Faults diagnostic system 69 8 16 Microcontroller alarms overview 7...

Page 5: ...speed and torque control 2 SenseCoils version using special auxiliary windings inside the motor instead of an encoder is realised the motor speed and torque control 3 Sensorless version using only the...

Page 6: ...temperature range 30 C 40 C Maximum inverter temperature at full power 85 C 2 2Technical specifications ACE2 Power Inverter for AC asynchronous 3 phase motors Regenerative braking functions Can bus i...

Page 7: ...AF2ZP0CL ACE2 User Manual Page 7 85 2 3Block diagram...

Page 8: ...10 V The negative supply of the potentiometer has to be taken from CNA 9 GND or from CNA 5 REV 1ST SPEED if the diagnosis PEDAL WIRE KO is done In this case the hardware must be configured closing a j...

Page 9: ...hows the relationship of the motor voltage without signal acquisition being made The Right Hand Graph shows the same relationship after signal acquisition of the potentiometer 3 3Other analog control...

Page 10: ...B output For more details about encoder installation see also chapter 4 2 5 4 Note The encoder resolution and the motor poles pair the controller can handle is specified in the home page display of t...

Page 11: ...ection must be comprised in the range 13 Nm 15Nm For the optimum inverter performance the cables to the battery should be run side by side and be as short as possible 4 1 2 Contactors The main contact...

Page 12: ...e horn solenoid valves and contactors not connected to the controller The heat generated by the power block must be dissipated For this to be possible the compartment must be ventilated and the heat s...

Page 13: ...immunity of the system to disturbances a good choice would be to use a cable with a shield connected to the frame of the truck Sometimes it is sufficient a simple double wire cable or a duplex cable...

Page 14: ...in power for example a traction and a pump motor controller and a third module works with less current the best way to deal this configuration is to create a common ground point star configuration U C...

Page 15: ...rimped contacts are completely inserted on the connector cavities U A cable connected to the wrong pin can lead to short circuits and failure so before turning on the truck for the first time verify w...

Page 16: ...ions 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 o...

Page 17: ...art Operation cannot begin if these operations are not carried out correctly Requests for drive must be made after closing the key switch 4 3 2 Safety Features U ZAPI controllers are designed accordin...

Page 18: ...ility to carry out machine validation based on existing norms EN12895 for industrial truck EN50081 2 for other applications EMC stands for Electromagnetic Compatibility and it represents the studies a...

Page 19: ...the type of controller materials and position of the wires and electronic components 1 EMISSIONS Three ways can be followed to reduce the emissions SOURCE OF EMISSIONS finding the main source of dist...

Page 20: ...CR low frequency chopper with ASYNCHRONOUS INVERTER because the ASYNCHRONOUS filter capacitors alter the SCR choppers work If it is necessary to use two or more control units traction lift for ex they...

Page 21: ...itivity at low speeds Voltage boost at the start and with overload to obtain more torque with current control The inverter can drive an electromechanical brake Hydraulic steering function traction inv...

Page 22: ...equence for operation is correct and if the output of accelerator unit is correct 2 Standby diagnosis in standby that checks watchdog circuit phase s voltages contactor driver current sensor can bus i...

Page 23: ...on potentiometer and brake potentiometer A10 CPOTBR Brake potentiometer wiper A11 SAFETY IN If not connected to Batt the MC and EB coil power output will be disabled In the COMBI configuration it is c...

Page 24: ...ive 12 V 5 V output keep load 1 kohm 0 5 kohm A3 CPOT Lifting potentiometer wiper A4 LIFT ENABLE Input for potentiometer lifting enable input it is active HIGH A5 SPEED1 Input for first speed request...

Page 25: ...the load with cathode connected to Batt A20 CAN L Low level CAN BUS voltage I O A21 CAN H High level CAN BUS voltage I O A22 PTHERM Input for motor temperature sensor It is possible to use a digital o...

Page 26: ...Page 26 85 AF2ZP0CL ACE2 User Manual 7 DRAWING 7 1Mechanical drawing ACE2 Existing others versions with or without power fuse With heat sink 200x40x150mm longitudinal transversal...

Page 27: ...L ACE2 User Manual Page 27 85 7 2Mechanical drawing ACE2 Power Existing others versions with or without power fuse With heat sink 200x40x185mm transversal With heat sink 200x40x200mm transversal longi...

Page 28: ...Page 28 85 AF2ZP0CL ACE2 User Manual 7 3Connection drawing Traction configuration...

Page 29: ...AF2ZP0CL ACE2 User Manual Page 29 85 7 4Connection drawing Pump configuration...

Page 30: ...Page 30 85 AF2ZP0CL ACE2 User Manual 7 5Connection drawing Combi configuration...

Page 31: ...t of Parameters and changes to the inverter s configuration are made using the Digital Console The Console is connected to the B connector of the inverter 8 2Description of Console Connection Digital...

Page 32: ...Page 32 85 AF2ZP0CL ACE2 User Manual 8 3Description of Standard Console Menu 8 3 1 Traction configuration...

Page 33: ...AF2ZP0CL ACE2 User Manual Page 33 85 8 3 2 Pump configuration...

Page 34: ...en released debouncing function 3 HOUR COUNTER RUNNING the counter registers travel time only KEY ON the counter registers when the key switch is closed 4 CUTBACK MODE OPTION 1 PRESENT or OPTION 2 If...

Page 35: ...t and inversion is timed 10 2 5 POT ON when the potentiometer is under the half range level is backward When is over is forward Forward and backward microswitches are not present Enable is A4 11 BACKI...

Page 36: ...for more information 9 BATT MAX ADJ It adjusts the upper 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 m...

Page 37: ...GE 100 MAIN CONT V RID 70 The contactor will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70 of battery voltage Example 2 MAIN CONT VOLTAGE 70 MAIN C...

Page 38: ...ut are active or a movement of the truck is detected The hydraulic steering function request is also sent to the pump inverter by the can bus link The truck is electrically hold on a slope when the ti...

Page 39: ...se input not jet defined Need hardware change 8 SAFETY OUT 0 none fa comunque la diag all init per verificare il funzionamento 1 driver is for drive a safety in 2 general purpose standard function rev...

Page 40: ...is reduced to the half of the programmed value OFF the battery discharge level check is carried out but no alarm is signalled U Very important In the combi system pump traction the battery discharge c...

Page 41: ...e X point and also between the X point and the maximum potentiometer position but with two different slopes 5 THROTTLE Y POINT This parameter together with the THROTTLE X POINT changes the characteris...

Page 42: ...arning 11 CHECK UP TYPE It specifies the handling of the CHECK UP NEEDED warning NONE No CHECK UP NEENED warning OPTION 1 CHECK UP NEENED warning shown on the hand set and MDI after 300 hours OPTION 2...

Page 43: ...CONT VOLTAGE 100 MAIN CONT V RID 70 The load will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70 of battery voltage Example 2 MAIN CONT VOLTAGE 70...

Page 44: ...SAFETY IN 0 input allways closed bridged 1 safety_in_drived safety came from a different controller need a can handshake 2 general purpose input not jet defined Need hardware change 8 SAFETY OUT 0 no...

Page 45: ...go into the SET MODEL Menu 7 The display will shows the first OPTION HOUR COUNTER RUNNING 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 Desired OPTION appears BATTERY CHECK OFF 10...

Page 46: ...ADJUSTMENTS Menu appears 5 ADJUSTMENTS appears on the display CONFIG MENU ADJUSTMENTS 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will shows SET BATTERY TYPE BATTERY TYPE 48V 8 Press R...

Page 47: ...Menu appears 5 ADJUSTMENTS appears on the display CONFIG MENU ADJUSTMENTS 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will show SET BATTERY TYPE SET BATTERY TYPE 80V 8 Press SET UP to...

Page 48: ...display will show the first OPTION SET BATTERY TYPE 48V 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 ADJUST BATTERY appears ADJUSTMENT BATTERY 50 2V 10 Press SET UP or SET DOWN...

Page 49: ...1 It specifies the motor acceleration at ACC PROF FREQ 1 Hz At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases 4 ACCELERATION 2 It specifies the motor a...

Page 50: ...me needed to decelerate the traction motor from 100Hz to 0Hz 12 PEDAL BRAKING Seconds It controls the deceleration ramp when the pedal position is changed but not completely released The parameter set...

Page 51: ...urve only if the EPS is present 25 STEER DEAD ANGLE Under this angle the curve cutback is not applied only if the EPS is present 26 AUXILIARY TIME Time units value seconds For the encoder version it d...

Page 52: ...the message on the console Parameters modified and optimized on one unit can be stored by the console SAVE and then released RESTORE on another inverter thus allowing fast and standardized settings se...

Page 53: ...time needed to decelerate the traction motor from 100Hz to 0Hz 9 MAX SPEED LIFT It determines the pump maximum speed when LIFT ENABLE switch is closed 10 1ST SPEED COARSE It determines the pump maximu...

Page 54: ...value for each parameter In the table is also present the parameters resolution PARAMETER UNIT MIN VALUE MAX VALUE RESOLUTION ACCELERATION 0 Sec 0 3 10 0 1 ACCELERATION 1 Sec 0 3 10 0 1 ACCELERATION...

Page 55: ...ext parameter 7 The names of the Parameters appear on the Display INV ACCEL 0 1 8 When the desired Parameter appears the Display will show the parameter value Press either SET UP Top Right or SET DOWN...

Page 56: ...r temperature C accelerator V handle seat switch ON OFF handle seat switch ON OFF lifting control V forward switch ON OFF lifting enable ON OFF backward switch ON OFF 1st speed switch ON OFF cutback s...

Page 57: ...ad 9 RELEASE BRAKING Operate the machine at full speed Release the accelerator pedal Adjust the level to your requirements If the machine is a forklift check the performance with and without load 10 I...

Page 58: ...ng the table on Chapter 8 5 2 6 Set the Acceleration and Deceleration Delay requirements for the pump 7 Set the FREQUENCY CREEP level starting from 0 Hz The pump should just turn when the request micr...

Page 59: ...P VALUE This is the difference of speed between the rotating field and the shaft of the motor expressed in the same unit of the frequency 7 CURRENT RMS Root Mean Square value of the motor current 8 MO...

Page 60: ...percentage of the full voltage 4 FREQUENCY This is the frequency of the voltage and current supplied to the motor 5 ENCODER This is the speed of the motor expressed in the same unit of the frequency t...

Page 61: ...F GND non active entry of open switch 17 3RD SPEED SWITCH Status of the third speed switch of the pump ON GND active entry of closed switch OFF VB non active entry of open switch 18 HYDRO SPEED REQ St...

Page 62: ...hows MAIN MENU TESTER 6 Press ENTER to go into the TESTER function 7 The first variable to be tested is shown on the Display BATTERY VOLTAGE 8 Press either ROLL UP or ROLL DOWN buttons until your desi...

Page 63: ...Zapi Display AE2T2B ZP0 12 24V 400A 00000 2 Press ENTER to go into the General menu 3 The Display will show MAIN MENU PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until SAVE PARAM appears on...

Page 64: ...ing restored Flow Chart showing how to use the RESTORE function of the Digital Console 1 Opening Zapi Display AE2T2B ZP0 12 24V 400A 00000 2 Press ENTER to go into the General menu 3 The Display will...

Page 65: ...ng to the minimum level The two graphs show the output voltage from a non calibrated potentiometer with respect to the mechanical zero of the control lever MI and MA indicate the point where the direc...

Page 66: ...ut Both directions can be shown VACC SETTING 4 8 4 8 8 Press ENTER to clear these values Display will show 0 0 9 Select Forward Direction close any interlock switches that may be in the system MIN VAC...

Page 67: ...Level 10 These two settings are the Bat Max Adj and the Bat Min Adj It is possible to adapt the Battery Charge Detection to your specific battery by changing the above two settings e g if the Battery...

Page 68: ...ry alarm occurred 4 And the inverter temperature when the first event of every alarm occurred This function permits a deeper diagnosis of problems as the recent history can be revised 4 NOTE if the sa...

Page 69: ...DOWN returns to the most recent 9 If an Alarm has not occurred the Display will show ALARM NULL CODE 00007 03 18 C 10 When you have finished looking at the Alarms press OUT to exit the ALARMS menu 11...

Page 70: ...oltage and the nominal battery voltage is greater than 20 of Vbatt nom MC is not closed EB is applied traction pump stopped Start up Traction Pump Request Capacitor charge MDI code allarm 60 Power cap...

Page 71: ...circuit is damaged MC is not closed EB is applied Traction Pump stopped Start up Traction Pump request Power mos shorted MDI code allarm 89 Short circuit on the power Mosfets MC is not closed EB is a...

Page 72: ...mp Request Contactor open MDI code allarm 77 The MC coil has been driven but MC does not close MC is opened EB is applied Traction Pump stopped Start up immediately after MC closing Stand by running T...

Page 73: ...ts gives frozen value on all of the converted signals for more than 400msec The goal of this diagnosis is to detect a failure of the A D converter or a problem in the code flow that omits the refreshi...

Page 74: ...is a problem in the controller power section 5 COIL SHORT HW KO Cause The hardware circuits which manages short circuits protection of LC and EB AUX coils has a problem Troubleshooting This type of fa...

Page 75: ...r voltage so it is suggested to check 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 e...

Page 76: ...ftware checks the power bridge it turns on alternatingly the Low side and High side Power Mosfets and expects the phases voltage to decrease down to BATT increase up to Batt If the phases voltage do n...

Page 77: ...tact closer properly with a good contact If no problem are found on the motors the problem is inside the controller replace it 18 STBY I HIGH Cause The current transducer or the current feedback circu...

Page 78: ...ause This alarm occurs when there is a short circuit of the MC coils connected to CNA 16 output After the overload condition has been removed the alarm exits automatically by releasing and then enabli...

Page 79: ...oting This type of fault is not related to external components replace the ACE2 logic board 30 ENCODER ERROR Cause This fault is signalled in following conditions the frequency supplied to the motor i...

Page 80: ...reduced Continuous Brake run out The Brake potentiometer input is at the maximum value without the HB request No effect the warning is only displayed through the console Continuous Traction Pump requ...

Page 81: ...cked and nothing was found replace the ACE logic board 3 VACC OUT OF RANGE Cause The CPOT input red by the microcontroller is not comprised in the range Vacc_min Vacc_max programmed through the PROGRA...

Page 82: ...on request is done Troubleshooting The possible reasons for this alarm are use the readings in the TESTER to facilitate the troubleshooting The HB switch is damaged so it does not close the input CNA...

Page 83: ...le manual Switch the key off and on to check the result If the alarm occurs permanently it is necessary to replace the controller If the alarm disappears the previously stored parameters will have bee...

Page 84: ...350 A strip UL Fuse 24V 500 C16586 Protected 250 A strip UL Fuse 36 48V 350 C16603 Protected 200 A strip UL Fuse 80V 300 C16520 10 A 20 mm Control Circuit Fuse All C29523 SW 180 80 V Single Pole Cont...

Page 85: ...rts used should be original Beware of NON ORIGINAL PARTS The installation of this electronic controller should be made according to the diagrams included in this Manual Any variations or special requi...

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