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AFFZP0BB – ACE3 – User Manual

Connector B

B1

PEV

Connect the positive supply of electrovalves (EV1, EV2,
EV3, EV4, EV5) to this pin. Take the positive supply
immediately after the main contactor.

B2

ANIN3

Free analog input.

B3

ANIN5

Free analog input.

B4

3RD

Third-speed input, to be connected to the 3

rd

-speed

microswitch, active high.

B5

4TH

Fourth-speed input, to be connected to the 4

th

-speed

microswitch, active high.

B6

2ND

Second-speed input, to be connected to the 2

nd

-speed

microswitch, active high.

B7

SH1/SIN

First Hall-sensor input, active low. Using a special
hardware configuration it is possible to use it for the sin
signal of a sin/cos sensor.

B8

PSENS

Positive supply 12 V / 5 V for Hall sensors (or sin/cos
sensor).

B9

NEV5

Output for the voltage-controlled PWM-modulated EV5
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.

B10

ANIN5

Free analog input.

B11

5TH

Fifth-speed input, to be connected to the 5

th

-speed

microswitch, active 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

1ST

First-speed input, to be connected to the 1

st

-speed

microswitch, active high.

B14

SH2/COS

Second Hall-sensor input, active low. Using a special
hardware configuration it is possible to use it for the cos
signal of a sin/cos sensor.

B15

NSENS

Negative supply for Hall sensors (or sin/cos sensor).

B16

NEV1

Output for the voltage-controlled PWM-modulated EV1
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.

B17

NEV2

Output for the voltage-controlled PWM-modulated EV2
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.

B18

NEV3

Output for the voltage-controlled PWM-modulated EV3
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.

B19

NEV4

Output for the voltage-controlled PWM-modulated EV4
electrovalve; 1 A maximum continuous current (driving to
-Batt). Freewheeling diode to B1 is built-in.

B20

CAN_L2

CAN bus 2 low-level signal.

B21

CAN_H2

CAN bus 2 high-level signal.

B22

SH3

Third Hall-sensor input, active low.

B23 FREE

Free

pin.

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Содержание ACE3

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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