Zapi ACE3 User Manual Download Page 5

Page: 5 / 139

AFFZP0BB – ACE3 – User Manual

Page – 5/139

7.2.5

HARDWARE SETTING .............................................................................. 61

7.2.6

HYDRO SETTING ...................................................................................... 62

7.3

TESTER function ...................................................................................................... 63

7.3.1

Master microcontroller ................................................................................ 63

7.3.2

Supervisor microcontroller .......................................................................... 69

7.4

Set-up procedure for traction inverter ....................................................................... 70

7.4.1

Sin/cos-sensored case ............................................................................... 71

7.5

Set-up procedure for pump inverter ......................................................................... 72

OTHER FUNCTIONS .......................................................................................................... 73

8.1

PROGRAM VACC function ...................................................................................... 73

8.2

PROGRAM LIFT / LOWER function ......................................................................... 74

8.3

PROGRAM STEER function .................................................................................... 74

8.4

Acceleration time ...................................................................................................... 75

8.5

Deceleration time .................................................................................................... 76

8.6

Acceleration smoothness ....................................................................................... 77

8.7

Steering curve ......................................................................................................... 78

8.8

Throttle response ..................................................................................................... 79

8.9

NLC & NEB output ................................................................................................... 80

8.10

Battery-charge detection .......................................................................................... 81

8.11

EVP control .............................................................................................................. 82

8.12

Torque profile ........................................................................................................... 84

8.13

Steering table ........................................................................................................... 85

FAULTS DIAGNOSTIC SYSTEM ....................................................................................... 86

9.1

Alarms – Master uC .................................................................................................. 86

9.1.1

Troubleshooting of master-uC alarms ........................................................ 90

9.2

Alarms – Supervisor uC.......................................................................................... 103

9.2.1

Troubleshooting of supervisor-uC alarms ................................................. 104

9.3

Warnings – Master uC ............................................................................................ 107

9.3.1

Troubleshooting of master-uC warnings ................................................... 110

9.4

Warnings overview (supervisor uC) ........................................................................ 120

9.4.1

Troubleshooting of supervisor-uC warnings ............................................. 120

SPARE PARTS ................................................................................................................. 122

PERIODIC MAINTENANCE .............................................................................................. 123

APPENDICES ................................................................................................................... 124

Summary of Contents for ACE3

Page 1: ...DUSTRIAL 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 ACE3 INVERTER Publication N AFF...

Page 2: ...changes 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 ther...

Page 3: ...r 10 2 4 Functional features 11 2 5 Diagnoses 12 3 DRAWINGS 13 3 1 Mechanical drawing ACE3 ACE3 Power 13 3 2 Connection drawing ACE3 Traction Standard 14 3 3 Connection drawing ACE3 Traction Premium 1...

Page 4: ...r 30 6 2 2 Wirings power cables 30 6 2 3 Wirings CAN bus connections and possible interferences 31 6 2 4 Wirings I O connections 33 6 2 5 Connection of the encoder 33 6 2 6 Connection of a Sin Cos sen...

Page 5: ...8 5 Deceleration time 76 8 6 Acceleration smoothness 77 8 7 Steering curve 78 8 8 Throttle response 79 8 9 NLC NEB output 80 8 10 Battery charge detection 81 8 11 EVP control 82 8 12 Torque profile 8...

Page 6: ...12 1 7 Alarm Logbook 129 12 2 Appendix B Zapi Smart Console user guide 130 12 2 1 Operational Modes 130 12 2 2 The keyboard 131 12 2 3 Home Screen 131 12 2 4 Connected 132 12 2 5 How to modify paramet...

Page 7: ...t improvement all data in this document are subject to change or correction without prior notice 1 1 3 Warnings and notes In this manual special attention must be paid to information presented in warn...

Page 8: ...f about 10 100 Ohm between Batt and Batt terminals of the inverter 1 2 2 OEM s Responsibility Zapi motor controllers are intended for controlling motors in electric vehicles These controllers are supp...

Page 9: ...ted sensorless and sense coil control Driver for line contactor coil Driver for electromechanical brake Drivers for PWM modulated voltage controlled electrovalves and for one PWM modulated current con...

Page 10: ...48V 325 A RMS 1 hour current rating ACE3 PW 80V 275 A RMS Operating frequency 8 kHz External temperature range 30 C 40 C Maximum inverter temperature at full power 85 C 4 Internal algorithms automati...

Page 11: ...low speed Voltage boost at the start and with overload to obtain more torque with current control Integrated driver for an electromechanical brake Hydraulic steering function a Traction inverter The t...

Page 12: ...ct and if the accelerator unit is in the correct position 2 Diagnosis during standby that checks watchdog circuits phase voltages contactor driver current sensors and CAN bus interface 3 Diagnosis dur...

Page 13: ...DRAWINGS 3 1 Mechanical drawing ACE3 ACE3 Power 0 5 X 45 R 0 5 1 2 A3 ACE3 PREMIUM 200X40X230 LONGITUDINAL HEAT SINK WITH POWER FUSE 1 1 AS 21 10 11 AFFZP7DA Other versions without power fuse with bas...

Page 14: ...Page 14 139 AFFZP0BB ACE3 User Manual 3 2 Connection drawing ACE3 Traction Standard...

Page 15: ...AFFZP0BB ACE3 User Manual Page 15 139 3 3 Connection drawing ACE3 Traction Premium...

Page 16: ...Page 16 139 AFFZP0BB ACE3 User Manual 3 4 Connection drawing ACE3 Pump Standard...

Page 17: ...AFFZP0BB ACE3 User Manual Page 17 139 3 5 Connection drawing ACE3 Pump Premium...

Page 18: ...eferred to as A where A denotes the connector name and the pin number from 1 to 23 ACE3 Standard 23 poles Ampseal connector ACE3 Premium is equipped with two equal 23 poles Ampseal connectors Each of...

Page 19: ...tive high A12 CAN_T1 CAN termination If it is connected with A21 CAN_H1 it introduces the 120 Ohm termination resistance between CAN_L1 and CAN_H1 A13 SR HB Speed reduction request or handbrake reques...

Page 20: ...A12 CAN_T1 CAN termination If it is connected with A21 CAN_H1 it introduces the 120 Ohm termination resistance between CAN_L1 and CAN_H1 A13 SR Speed reduction request input Active when the switch is...

Page 21: ...ive high A12 CAN_T1 CAN termination If it is connected with A21 CAN_H1 it introduces the 120 Ohm termination resistance between CAN_L1 and CAN_H1 A13 SR HB Speed reduction request or handbrake request...

Page 22: ...e high B12 CAN_T2 CAN termination If it is connected to B21 CAN_H2 it introduces the 120 Ohm termination resistance between CAN_L2 and CAN_H2 B13 BACKING BW Backward inching request input It must be c...

Page 23: ...12 CAN_T1 CAN termination If it is connected with A21 CAN_H1 it introduces the 120 Ohm termination resistance between CAN_L1 and CAN_H1 A13 SR Speed reduction request input Active when the switch is o...

Page 24: ...T2 CAN termination If it is connected to B21 CAN_H2 it introduces the 120 Ohm termination resistance between CAN_L2 and CAN_H2 B13 1ST First speed input to be connected to the 1st speed microswitch ac...

Page 25: ...pter 3 should be sized according to the number of motor controllers connected to it 10 A fuse is recommended and the current absorption of the KEY input input power under 15 W 5 2 Digital Inputs Digit...

Page 26: ...middle in combination with a couple of travel demand switches The procedure for automatic acquisition of the potentiometer signal is carried out using the Console by means of the PROGRAM VACC function...

Page 27: ...d function Each driving potentiometer should be in a three wire configuration its resistance should be within the 0 5 10 k range the current within the 1 5 30 mA range and the voltage signal from 0 to...

Page 28: ...or and Hall sensors ACE3 Premium provides a special interface to connect an absolute sin cos sensor or three Hall sensors for special applications that use brushless motor For more details about senso...

Page 29: ...rs Main contactor must always be installed The output driving the coil is modulated with a 1 kHz PWM basing on the setting of two parameters MC VOLTAGE and MC VOLTAGE RED After an initial delay of abo...

Page 30: ...Fit transient suppression devices to the horn solenoids and contactors not connected to the controller Ensure the compartment to be ventilated and the heat sinking materials ample The heat sinking mat...

Page 31: ...he immunity of the system to disturbances a good choice would be to use shielded cables where the shield is connected to the frame of the truck Sometimes it is sufficient a not shielded two wire cable...

Page 32: ...wise if two controllers are similar in power for example a traction and a pump motor controller and a third module works with less current for example a steering controller the best way to address thi...

Page 33: ...onto the bus 6 2 4 Wirings I O connections After crimping the cables verify that all strands are entrapped in the wire barrel Verify that all the crimped contacts are completely inserted in the connec...

Page 34: ...ce between two motor terminals is of the shape sinusoidal To control PMAC motor with Zapi inverter it is necessary to install an absolute Sin Cos sensor The Sin Cos sensor power supply can be 5 or 12...

Page 35: ...supply B7 HS1 Hall sensor 1 B14 HS2 Hall sensor 2 B22 HS3 Hall sensor 3 Connection of Hall sensors U VERY IMPORTANT It is absolutely mandatory to specify in the commercial order the type of sensor to...

Page 36: ...se battery polarity and for safety reasons Connection errors All inputs are protected against connection errors Thermal protection If the controller temperature exceeds 85 C the maximum current is red...

Page 37: ...s any responsibility for non compliance malfunctions and failures if correct testing is not made The machine manufacturer holds the responsibility to carry out machine validation based on existing nor...

Page 38: ...failures in the electronic devices the type of failure can vary from a temporary malfunction to a definitive failure of the electronic device 4 IMPORTANT NOTE it is always much easier and cheaper to a...

Page 39: ...ct to truck frame all the parts of the truck which can be touched by the operator who is most of the time the source of ESD 6 5 Various suggestions Never connect SCR low frequency chopper with asynchr...

Page 40: ...ION MODE STEER TABLE WHEELBASE MM FIXED AXLE MM STEERING AXLE MM REAR POT ON LEFT DISPLAY TYPE ABS SENS ACQUIRE SET BATTERY ADJUST KEY VOLT ADJUST BATTERY SET POSITIVE PEB SET PBRK MIN SET PBRK MAX MI...

Page 41: ...RQUE CONTROL is ON i e the time needed to decrease the torque from the maximum value down to the minimum one ACCELER DELAY T TM P CO 0 1 s 25 5 s by steps of 0 1 s This parameter defines the accelerat...

Page 42: ...ate the motor from 100 Hz down to 0 Hz A special software feature manages the deceleration ramp depending on the starting speed see paragraph 8 5 MAX SPEED FORW T TM 0 100 by 1 steps This parameter de...

Page 43: ...CK T TM 1 100 by 1 steps This parameter defines the maximum traction speed when the steering angle is equal to the STEER ANGLE 2 angle The parameter represents a percentage of TOP MAX SPEED FREQUENCY...

Page 44: ...e is actually released The releasing delay of the brake can be measured or it can be found in the datasheet AUXILIARY TIME T TM P CO 0 s 10 s by steps of 0 1 s For the encoder version this parameter d...

Page 45: ...ctive or the DC motor power bridge is active or one of the valve outputs is active Note options 2 4 5 and 6 are not effective on ACE3 HM CUSTOM 2 OPT T TM P CO 0 6 This parameter decides the configura...

Page 46: ...ace on a slope for a defined time ON the stop on ramp feature truck electrically held on a ramp is performed for a time set in the AUXILIARY TIME parameter After this interval the behavior depends on...

Page 47: ...uick inversion functionality NONE the quick inversion function is not managed BRAKE upon a quick inversion request the motor is braked TIMED the quick inversion function is timed upon a QI request the...

Page 48: ...out enable switch without enable dead band 9 Z type pot high to low value with direction switches without enable switch with enable dead band 10 Z type pot high to low value without direction switches...

Page 49: ...is not driven ON main contactor is in standalone configuration Diagnoses are performed and MC is closed after key on only if they have passed OPTION 1 for a traction pump setup with only one main cont...

Page 50: ...on ramp is also proportional to the speed setpoint so that the acceleration duration results equal to ACCEL DELAY See paragraph 8 4 EVP TYPE A NONE DIGITAL This parameter defines how the output A19 EV...

Page 51: ...steering table NONE The inverter does not follow any predefined steering table but it creates a custom table according to WHEELBASE MM FIXED AXLE MM STEERING AXLE and REAR POT ON LEFT parameters OPTIO...

Page 52: ...F ON This parameter activates the acquisition of motor speed sensor used for PMSM Permanent Magnets Synchronous Motor Contact Zapi Technicians for a detailed description of the acquisition procedure B...

Page 53: ...t records the maximum value of brake potentiometer when the brake is analog MIN LIFT DC Read Only T TM TS P 0V 25 5V by steps of 0 1V It records the minimum value of lifting potentiometer when the lif...

Page 54: ...12 8 12 7 by steps of 0 1 This parameter defines the start up level of the battery charge table in order to evaluate the battery charge at key on See paragraph 8 10 BDI RESET T TM P CO 0 100 by 1 step...

Page 55: ...raction speed is reduced to CURVE CUTBACK For steering wheel angles between STEER ANGLE1 and STEER ANGLE 2 traction speed is reduced linearly from CURVE SPEED 1 to CURVE CUTBACK See paragraph 8 7 SPEE...

Page 56: ...es the duty cycle of the PWM applied to EV5 output B9 MC VOLTAGE A 0 100 by 1 steps This parameter specifies the duty cycle tON TPWM of the PWM applied to the main contactor output A16 during the firs...

Page 57: ...TM P CO 60 C 190 C by steps of 1 C This parameter defines the maximum motor temperature permitted above which the controller stops driving the motor A SENS MAX SE A Only sin cos customized HW Volt Thi...

Page 58: ...r enables or disables the linear compensation for the current sensors NOTE only Zapi technicians can change this value through a special procedure DIS CUR FALLBACK A OFF ON This parameter disables or...

Page 59: ...nal amplitude The dither signal is a square wave added to the proportional valve set point In this way the response to set point variations results optimized This parameter is a percentage of the valv...

Page 60: ...offset different from 0 in order to enable the channel VDC START UP LIM T TM P CO 0 255 by 1 steps This parameter defines the battery voltage as percentage of the nominal voltage above which delivere...

Page 61: ...ncoder 1 sin cos sensor 2 incremental encoder sin cos sensor 3 incremental encoder sin cos sensor index 4 PWM absolute sensor incremental encoder index 5 resolver ROTATION CW ENC A OPTION 1 OPTION 2 T...

Page 62: ...action motor It must be set equal to MOTOR P PAIRS 1 otherwise the controller raises an alarm 7 2 6 HYDRO SETTING HYDRO SETTING Parameter Allowable range Description HYDRO TIME A 0 s 200 s steps of 1...

Page 63: ...lists the master microcontroller data that can be monitored through the TESTER function TESTER Master Parameter Unit of measurement resolution Description KEY VOLTAGE A Volt 0 1 V Key voltage measure...

Page 64: ...ons inverter temperature motor temperature etc ID FILTERED RMS A Ampere 1 A Projection of the current vector on the d axis expressed in root mean square Ampere IQ FILTERED RMS A Ampere 1 A Projection...

Page 65: ...al Brake Quick Inversion input A11 B13 HS T TM OFF ON Status of the Hard Soft input B13 A4 FW SW T TM TS OFF ON Status of the forward input A4 A4 ENABLE T TM TS OFF ON Status of the driving demand inp...

Page 66: ...11 A13 CUTBAC1 P OFF ON Status of the speed reduction input A13 NODE ID CO 0 56 Node ID setting for CAN OPEN Protocol TARGET SPEED CO 10 Hertz 1 daHz This value shows the speed setpoint transmitted ov...

Page 67: ...4 A Volt 0 01V Voltage of the analog signal on B10 B3 POT 5 A Volt 0 01V Voltage of the analog signal on B3 SIN FB INPUT A Only for BLE3 with sin cos sensor Volt 0 01 V Voltage of sine input B7 COS FB...

Page 68: ...gnal acquired during the absolute sensor acquisition automatic procedure A SENS OFFSET CR A Only for BLE3 with sin cos sensor Digital units Offset of the encoder cosine signals acquired during the abs...

Page 69: ...pressed in the same unit of FREQUENCY Hz A4 A OFF ON Status of input A4 A5 A OFF ON Status of input A5 A11 A OFF ON Status of input A11 B13 A OFF ON Status of input B13 B6 A OFF ON Status of input B6...

Page 70: ...the PROGRAM VACC procedure see paragraph 8 1 Set the maximum current for traction and braking in MAX CURRENT TRA and MAX CURRENT BRK see paragraph 7 2 1 Set the motor related parameters It is suggest...

Page 71: ...oes not spin it vibrates or speed on display oscillates too much stop the acquisition procedure releasing the FW or BW command see troubleshooting at the paragraph end The first phase where motor is s...

Page 72: ...o your set up see paragraph 7 2 3 Check the wiring and that all commands are functioning Use the TESTER function to have real time feedback about their state Perform the accelerator acquisition using...

Page 73: ...e of the control lever Angles MI and MA indicate the points where the direction switches close while 0 represents the mechanical zero of the lever i e its rest position Also the relationship between m...

Page 74: ...ey are MIN LIFT DC MAX LIFT DC MIN LOWER MAX LOWER See paragraphs 12 1 4 or 12 2 7 for acquiring procedure 8 3 PROGRAM STEER function This enables the adjustment of the minimum and maximum useful sign...

Page 75: ...d differently by software for final speed setpoint values above or below 100 Hz Case 1 black trace in the graph Final speed setpoint 100 Hz ACCEL DELAY 2 5 s Acceleration time results 2 5 s Case 2 red...

Page 76: ...he deceleration time results 2 5 s Case 2 red trace in the graph Initial speed 60 Hz Final speed setpoint 10 Hz DECEL BRAKING 2 5 s The deceleration rate is re scaled so that the deceleration time res...

Page 77: ...ameters define a parabolic profile to the acceleration or deceleration ramp near 0 rpm Values have not a phisycal meaning 1 means linear ramp higher values up to 5 result in smoother the accelerations...

Page 78: ...fine a speed reduction profile dependent on the steering wheel angle The profile is valid both for positive and negative angle values Example Three wheel CB truck Permitted steering wheel angles 90 90...

Page 79: ...X3 POINT of MAX VACC THROTTLE Y3 POINT of MAX SPEED The speed remains at the FREQUENCY CREEP value as long as the voltage from the accelerator potentiometer is below THROTTLE 0 ZONE Basically this de...

Page 80: ...applied after that necessary to keep the contactor closed or brake disengaged according to this formula Figure 3 NMC NEB Output management Example 1 MC VOLTAGE 100 MC VOLTAGE RED 70 The contactor is c...

Page 81: ...h a threshold value which comes as function of the actual charge percentage by this comparison a new charge percentage is obtained 3 The threshold value can be changed with the BDI ADJ STARTUP paramet...

Page 82: ...ead EVP current is kept at zero for potentiometer voltages below MIN LOWER EVP analog control EVP TYPE DIGITAL If EVP is set to work as an on off valve the MIN EVP parameter is disabled and the curren...

Page 83: ...the same way when the lowering request is released while the set point is at the maximum the current is linearly reduced down to the minimum in a time equal to CLOSE DELAY and after that transition is...

Page 84: ...for the maximum torque demand through set points in the weakening area for matching two goals 1 Not overtaking the maximum torque profile of the motor 2 Superimposing a limiting profile to the maximu...

Page 85: ...table NONE custom steering table according to the following parameters o WHEELBASE MM distance between the front axle and the rear axle of the truck o FIXED AXLE MM axle width of the axle where the f...

Page 86: ...code Effect Condition Restart procedure CAN OPEN CODE MDI CODE ZAPI CODE LED CODE VDC LINK OVERV MC is not closed EB is applied Traction Pump valves stopped Stand by running Valves or Traction Pump Re...

Page 87: ...raction Pump Request 0xFFE6 22 230 22 IQ MISMATCHED Traction is stopped Running Valves or Traction Pump Request 0xFFF5 24 245 24 INIT VMN LOW 01 INIT VMN LOW 02 INIT VMN LOW 03 MC is not closed EB is...

Page 88: ...Traction Pump Request 0x2311 53 53 53 OVERLOAD Traction is stopped Running Key re cycle 0xFFB4 57 180 57 CAPACITOR CHARGE MC is not closed EB is applied Traction Pump valves stopped Start up Valves o...

Page 89: ...pplied traction pump stopped Running Key re cycle 0x5001 27 194 27 POS EB SHORTED MC is not closed EB is applied Traction Pump valves stopped Start up Key re cycle 0x3223 84 195 84 VDC OFF SHORTED MC...

Page 90: ...t A1 Undervoltage threshold is 11V for 36 48V controllers and 30 V for 80V controllers Troubleshooting fault at startup or in standby Fault can be caused by a key input signal characterized by pulses...

Page 91: ...case no failures problems have been found the problem is in the controller which has to be replaced 6 CTRAP THRESHOLD Cause This alarm occurs when a mismatch is detected between the setpoint for the o...

Page 92: ...n occurs again ask for assistance to a Zapi technician The fault condition could be affected by wrong adjustments of motor parameters 11 FIELD ORIENT KO Cause The error between the Id d axis current s...

Page 93: ...20 of the nominal battery voltage the alarm is raised and the main contactor is not closed Troubleshooting Check if an external load in parallel to the capacitor bank which sinks current from the cap...

Page 94: ...he impedance between U V and W terminals and Batt terminal of the controller Check the motor leakage to truck frame If the motor connections are OK and there are no external low impedance paths the pr...

Page 95: ...closes properly with a good contact o if no problem is found the problem is inside the controller Replace it 19 VMN HIGH Cause 1 Before switching the LC on the software checks the power bridge it tur...

Page 96: ...ut of range Troubleshooting Ask for assistance to a Zapi technician about the correct adjustment of the motor parameters 23 SEAT MISMATCH Cause This alarm can appear only in a Traction Pump configurat...

Page 97: ...he wires crimping Check the mechanical installation of the encoder if the encoder slips inside its housing it will raise this alarm Also the electromagnetic noise on the sensor can be the cause for th...

Page 98: ...ower capacitors get discharged it means that the main contactor is open Troubleshooting LC contacts are not working Replace the LC If LC contacts are working correctly contact a Zapi technician 31 CON...

Page 99: ...urs permanently it is necessary to replace the logic board 35 DRIVER SHORTED Cause The driver of the LC coil is shorted Troubleshooting Check if there is a short or a low impedance pull down between N...

Page 100: ...E reading shows the same value as the key voltage measured with a voltmeter on pin A1 If it does not match then modify the ADJUST BATTERY parameter according to the value read by the voltmeter Replace...

Page 101: ...the battery voltage if it is out of range replace the battery In case the problem is not solved replace the logic board 45 POWERMOS SHORTED Cause The DC link voltage drops to zero when a high side MO...

Page 102: ...olved replace the logic board 48 WRONG SET BATTERY Cause The measured battery voltage is not the right one for the inverter Troubleshooting Check if the battery voltage measured between the Batt and B...

Page 103: ...19 19 LOGIC FAILURE 3 MC is opened EB is applied traction pump stopped Stand by running Valves or Traction Pump Request 0XFF11 17 17 17 INPUT MISMATCH MC is opened EB is applied Traction Pump stopped...

Page 104: ...key input A1 Undervoltage threshold is 11V for 36 48V controllers and 30 V for 80V controllers Fault can be caused by a key input signal characterized by pulses below the undervoltage threshold possib...

Page 105: ...est that involves the logic between master and supervisor microcontrollers Troubleshooting This alarm could be caused by a CAN bus malfunctioning which blinds master supervisor communication 7 WRONG R...

Page 106: ...alarm occurs when the A D conversion of the analog inputs returns frozen values on all the converted signals for more than 400 ms The goal of this diagnosis is to detect a failure in the A D converter...

Page 107: ...RT 0xFFAC 2 172 2 SIN COS D ERR Traction is stopped running Traction request 0xFFA8 3 168 3 ENCODER D ERR Traction is stopped running Traction request 0xFFA9 3 169 3 EVP DRIVER OPEN MC is opened the c...

Page 108: ...ased Traction Pump valves stopped Running Valves or Traction Pump Request 0x3224 42 246 42 EB COIL OPEN MC remain closed EB is applied the command is released Traction Pump valves stopped Start up Sta...

Page 109: ...ed Start up stand by running Traction request 0xFF4E 78 78 78 INCORRECT START Traction Pump motor is stopped Start up stand by Traction request 0xFF4F 79 79 79 FORW BACK Traction is stopped Start up s...

Page 110: ...ck if any other device on the CAN bus is in fault condition 2 TORQUE PROFILE Cause There is an error in the choice of the torque profile parameters Troubleshooting Check in the HARDWARE SETTING menu t...

Page 111: ...and cos signals If the motor direction is not correct swap two of the motor cables If the problem is not solved contact a Zapi technician 9 ENCODER D ERR Cause This alarm occurs only when the controll...

Page 112: ...ycle the key 14 THROTTLE PROG Cause A wrong profile has been set in the throttle profile Troubleshooting Set properly the throttle related parameters see paragraph 8 8 15 INCORRECT START Cause Incorre...

Page 113: ...BW input states through the TESTER function Check the wirings relative to the FW and BW inputs Check if there are failures in the microswitches If the problem is not solved replace the logic board 19...

Page 114: ...s in the microswitches If the problem is not solved replace the logic board 24 CURRENT GAIN Cause The maximum current gain parameters are at the default values which means the maximum current adjustme...

Page 115: ...motor thermal sensor is out of range Troubleshooting Check if the resistance of the sensor is what expected measuring its resistance Check the wiring If the problem is not solved replace the logic bo...

Page 116: ...onality of the accelerator potentiometer Acquire the maximum and minimum potentiometer value through the PROGRAM VACC function If the problem is not solved replace the logic board 34 STALL ROTOR Cause...

Page 117: ...CE3 Premium version is not connected to the battery or the voltage is different from expected This alarm occurs if one output among EVP EV1 EV2 EV3 EV4 and EV5 is present or the AUX OUT function is ac...

Page 118: ...ooting Check if there is a short circuit or a low impedance path between the negative terminal of the coils and BATT If the problem is not solved replace the logic board 42 EEPROM KO Cause A HW or SW...

Page 119: ...ccurs when the temperature sensor is open if digital or if it has overtaken the MAX MOTOR TEMP threshold if analog see paragraph 7 2 3 Troubleshooting Check the temperature read by the thermal sensor...

Page 120: ...INKS STEER SENS KO EB is applied traction pump stopped Continuous Key re cycle 0xFFC3 95 200 95 PARAM RESTORE No effect Start up Traction Pump request 0X000 14 209 14 EEPROM KO Controller works using...

Page 121: ...embedded memory storing the controller parameters This alarm does not inhibit the machine operations but it makes the truck to work with the default values Troubleshooting Execute a CLEAR EEPROM proce...

Page 122: ...strip UL Fuse 36 48V 650 A 36 48V 600 A C16589 Protected 400 A strip UL Fuse 80V 550 A C16588 Protected 350 A strip UL Fuse 80V 450 A C16520 10 A 20 mm Control Circuit Fuse All C29509 SW 200 80 V Sin...

Page 123: ...ld be original Beware NON ORIGINAL PARTS The installation of this electronic controller should be made according to the diagrams included in this manual Any variations or special requirements should b...

Page 124: ...de Windows Pc CAN Console uses standard Zapi communication protocol to display inverter information It provides all standard Zapi Console functions with the easier handling of Windows environment Besi...

Page 125: ...ve defined the CAN interface you have to choose which CAN device you want to connect to choose Connection Set Node or press the Set Node icon Once you have chosen the node you want to connect to start...

Page 126: ...eters will be saved as a csv file in order to be opened with Microsoft Excel or any other spreadsheet tool The file contains the whole list of parameter and for each one various data are available in...

Page 127: ...n Program Vacc menu When Acquire is pressed the PROGRAM VACC procedure starts Select the Enable switch if any Select the direction switch either forward or backward Depress the pedal to its maximum ex...

Page 128: ...switch either lift or lower Move the control sensor lift lower potentiometer to the correct position according to what you are acquiring Press Stop Teach button The procedure is the same for both lift...

Page 129: ...information 12 1 7 Alarm Logbook This window will display the alarms stored in the controller For every alarm will be shown the working hour at which it s occurred the motor temperature and the number...

Page 130: ...c converter Current loop serial connection Smart Console offers the same serial connection as the well known Console Ultra Main features of this operational mode are Current loop serial communication...

Page 131: ...ue associated with the selected item OK and ESC keys OK key is used either to confirm actions or to enter a submenu ESC is used either to cancel an action or to exit a menu F1 F2 F3 keys These buttons...

Page 132: ...f serial connection fails a NO COMMUNICATION warning will be shown after some seconds press ESC key and look for what is preventing the connection 4 Please notice the red dot appearing on the top righ...

Page 133: ...sired menu press OK to enter it 12 2 5 How to modify parameters From MAIN MENU enter the desired menu for example the PARAMETER CHANGE menu With UP and DOWN keys you can scroll the list once you have...

Page 134: ...s like SET OPTIONS ADJUSTMENT HARDWARE SETTING etc 12 2 6 PROGRAM VACC PROGRAM VACC menu has been slightly modified from old consoles Upon entering this menu the console shows the current programmed v...

Page 135: ...lue you want acquire press OK When OK is pressed the procedure starts select the Enable switch if any select the control switch if any either lift or lower move the control sensor lift lower potentiom...

Page 136: ...e to follow is the same described in previous paragraph 12 2 9 TESTER Compared to standard console Ultra the TESTER menu has been deeply modified Now it shows four variables at once use UP DOWN keys t...

Page 137: ...ontroller it has the possibility to download all parameters into a USB stick To use this function go into the menu SAVE PARAMETER USB in the MAIN MENU File format The complete list of parameters is sa...

Page 138: ...will be shown immediately Left key returns one level back in the directory tree it does not work in the root directory Esc returns to HOME SCREEN OK starts download When saving files the console crea...

Page 139: ...ubdirectory manually 3 Press OK to start parameter download A progression bar shows the ongoing process 4 When finished press ESC so to return to MAIN MENU USB stick can be removed safely Connect the...

Search results

Summary of Contents for ACE3

Reviews:

Brands by name

Popular brands

Zapi ACE3, User Manual

Search results

Summary of Contents for ACE3

Reviews:

Brands by name

Popular brands