Zapi ACE2 User Manual

Summary of 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 en user manual ace2 inverter.

  • Page 2

    Page - 2/85 af2zp0cl - ace2 - user manual copyright © 1975-2009 zapi s.P.A. All rights reserved the contents of this publication is a zapi s.P.A. Property; all related authorizations are covered by copyright. Any partial or total reproduction is prohibited. Under no circumstances will zapi s.P.A. Be...

  • Page 3: Contents

    Af2zp0cl - ace2 - user manual page - 3/85 contents 1 introduction ...................................................................................................................5 2 specification ........................................................................................................

  • Page 4

    Page - 4/85 af2zp0cl - ace2 - user manual 8.4.1 traction....................................................................................................... 34 8.4.2 pump .......................................................................................................... 39 8.5 parameter re...

  • Page 5: 1 Introduction

    Af2zp0cl - ace2 - user manual page - 5/85 1 introduction within the zapimos family, the ace-2 inverter (e stands for evolution) is the model suitable for control of 4.0 kw to 9.0 kw motors. It has been expressly designed for battery electric traction. It is fit for electric truck, material handling:...

  • Page 6: 2 Specification

    Page - 6/85 af2zp0cl - ace2 - user manual 2 specification 2.1 technical specifications ace2 inverter for ac asynchronous 3-phase motors regenerative braking functions can-bus interface flash memory (128 kbytes on-chip program memory) digital control based upon a microcontroller voltage:................

  • Page 7: 2.3 Block  Diagram

    Af2zp0cl - ace2 - user manual page - 7/85 2.3 block diagram.

  • Page 8: 3.1 Microswitches

    Page - 8/85 af2zp0cl - ace2 - user manual 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 re...

  • Page 9

    Af2zp0cl - ace2 - user manual page - 9/85 elements associated with the potentiometer, especially relating to the minimum level. The sequence of procedure is described in the programming console manual. The two graphs show the output voltage from a non-calibrated potentiometer with respect to the mec...

  • Page 10: 3.4 Speed  Feedback

    Page - 10/85 af2zp0cl - ace2 - user manual 3.4 speed feedback the motor control is based upon the motor speed feedback. The speed transducer is an incremental encoder, with two phases shifted at 90°. The encoder can be of different types: - power supply: +5 v or +12 v. - electric output: open collec...

  • Page 11: 4 Installation Hints

    Af2zp0cl - ace2 - user manual page - 11/85 4 installation hints in the description of these installation suggestions you will find some boxes of different colors, they mean: 4 these are information useful for anyone is working on the installation, or a deeper examination of the content u these are w...

  • Page 12

    Page - 12/85 af2zp0cl - ace2 - user manual 4.2 installation of the hardware u before doing any operation, ensure that the battery is disconnected and when all the installation is completed start the machine with the drive wheels raised from the floor to ensure that any installation error do not comp...

  • Page 13

    Af2zp0cl - ace2 - user manual page - 13/85 4.2.3 wirings: can connections and possible interferences 4 can stands for controller area network. It is a communication protocol for real time control applications. Can operates at data rate of up to 1 megabits per second. It was invented by the german co...

  • Page 14

    Page - 14/85 af2zp0cl - ace2 - user manual the black lines are the power cables. This is apparently a good layout, but can bring to errors in the can line. The best solution depends on the type of nodes (modules) connected in the network. If the modules are very different in terms of power, then the...

  • Page 15

    Af2zp0cl - ace2 - user manual page - 15/85 account thermal and voltage drop problems. 4 can advantages: the complexity of today systems needs more and more data, signal and information must flow from a node to another. Can is the solution to different problems that arise from this complexity - simpl...

  • Page 16

    Page - 16/85 af2zp0cl - ace2 - user manual connection of encoder with +12 v power supply. U very important 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 ...

  • Page 17

    Af2zp0cl - ace2 - user manual page - 17/85 4.3 protection and safety features 4.3.1 protection features the ace-2 is protected against some controller injuries and malfunctions: - battery polarity inversion it is necessary to fit a main contactor to protect the inverter against reverse battery polar...

  • Page 18: 4.4 Emc

    Page - 18/85 af2zp0cl - ace2 - user manual failure in the "safety" circuit, the microcontroller itself will bring the machine in a safe status. Suggested connection of "safety" circuit: - standalone configuration: it is suggested to connect safety input to the "seat" microswitch or to the "deadman" ...

  • Page 19

    Af2zp0cl - ace2 - user manual page - 19/85 simulate external undesired disturbances and verify the electronic devices response. 3) the second type of immunity, esd, concerns the prevention of the effects of electric current due to excessive electric charge stored in an object. In fact, when a charge...

  • Page 20: 4.5 Various  Suggestions

    Page - 20/85 af2zp0cl - ace2 - user manual time the source of esd. 4.5 various suggestions - never connect scr 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 + lif...

  • Page 21: 5 Operational Features

    Af2zp0cl - ace2 - user manual page - 21/85 5 operational features - speed control (three versions available: sensored, sense coil and sensorless as explained in the introduction section) . - optimum behaviour on a slope due to the speed feedback: - the motor speed follows the accelerator, starting a...

  • Page 22: 5.1 Diagnosis

    Page - 22/85 af2zp0cl - ace2 - user manual 5.1 diagnosis the microcontroller continually monitors the inverter and carries out a diagnostic procedure on the main functions. The diagnosis is made in 4 points: 1) diagnosis on key switch closing that checks: watchdog circuit, current sensor, capacitor ...

  • Page 23

    Af2zp0cl - ace2 - user manual page - 23/85 6 description of the connectors 6.1 connectors of the logic - traction configuration a1 key connected to the power supply through a microswitch (ch) with a 10 a fuse in series. A2 ppot potentiometer positive: 12 v / 5 v output; keep load > 1 kohm / 0.5 kohm...

  • Page 24

    Page - 24/85 af2zp0cl - ace2 - user manual 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 or analogue (ptc) sensor. A23 ntherm -batt. B1 pclrxd positive serial recep...

  • Page 25

    Af2zp0cl - ace2 - user manual page - 25/85 connected to -batt. A14 encb incremental encoder phase b input. A15 enc gnd encoder negative power supply. A16 nlc main contactor coil output. The coil is driven to negative reference. A17 plc/paux positive of the lc and auxiliary coil. A18 naux auxiliary c...

  • Page 26: 7 Drawing

    Page - 26/85 af2zp0cl - ace2 - user manual 7 drawing 7.1 mechanical drawing ace2 existing others versions (with or without power fuse): - with heat sink 200x40x150mm (longitudinal / transversal).

  • Page 27

    Af2zp0cl - ace2 - user manual page - 27/85 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).

  • Page 28

    Page - 28/85 af2zp0cl - ace2 - user manual 7.3 connection drawing - traction configuration.

  • Page 29

    Af2zp0cl - ace2 - user manual page - 29/85 7.4 connection drawing - pump configuration.

  • Page 30

    Page - 30/85 af2zp0cl - ace2 - user manual 7.5 connection drawing - combi configuration.

  • Page 31: Digital Console

    Af2zp0cl - ace2 - user manual page - 31/85 8 programming & adjustments using digital console 8.1 adjustments via console adjustment 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. 8.2 descrip...

  • Page 32

    Page - 32/85 af2zp0cl - ace2 - user manual 8.3 description 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

    Page - 34/85 af2zp0cl - ace2 - user manual 8.4 function configuration 8.4.1 traction using the config menu of the programming console, the user can configure the following functions (see "operational feature" chapter for an explanation of "hydraulic steering function"): submenu "set options" 1) disp...

  • Page 35

    Af2zp0cl - ace2 - user manual page - 35/85 - off: the stop on ramp feature is not performed. 7) aux output #1 - brake: output a18 drives an electromagnetic brake coil which is activated every time the traction motor is driven. - free: no function. - option#1: reverse alarm. A18 is active when input ...

  • Page 36

    Page - 36/85 af2zp0cl - ace2 - user manual 5) throttle 0 zone it establishes a deadband in the accelerator input curve (see also curve below). 6) throttle x point this parameter changes the characteristic of the accelerator input curve. 7) throttle y point this parameter changes the characteristic o...

  • Page 37

    Af2zp0cl - ace2 - user manual page - 37/85 12) check up done turn it on when the required maintenance service has been executed to cancel the check up needed warning. 13) check up type it specifies the handling of the check up needed warning: - none: no check up neened warning - option#1: check up n...

  • Page 38

    Page - 38/85 af2zp0cl - ace2 - user manual main cont v rid = 70% the ebrake will be closed with 70% of battery voltage applied to the coil and then the voltage will be reduced to 49% of battery voltage. Aux output stop on ramp a18 output behaviour on a slope brake on -it drives the coil of a electro...

  • Page 39

    Af2zp0cl - ace2 - user manual page - 39/85 submenu "special adjust" 1) adjustment#01 reserved. 2) adjustment#02 reserved. 3) set current it adjusts the regolation of maximum current. It shouldn’t be changed. 4) high adress reserved. 5) debug mode reserved. 6) inverter type it decides what kind of in...

  • Page 40

    Page - 40/85 af2zp0cl - ace2 - user manual 3: smart display connected 4: mdi can connected 2) tiller switch this option handles the input cna#6 . This input opens when the operator leaves the truck. It is connected to a key voltage when the operator is present. There are two levels: - handle: cna#6 ...

  • Page 41

    Af2zp0cl - ace2 - user manual page - 41/85 submenu "adjustments" 1) set battery type it selects the nominal battery voltage. 2) adjust battery fine adjustment of the battery voltage measured by the controller. 3) throttle 0 zone it establishes a dead band in the lift potentiometer input curve (see a...

  • Page 42

    Page - 42/85 af2zp0cl - ace2 - user manual 7) 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 more information. 8) adjustment #03 this parameter adjusts the updating of...

  • Page 43

    Af2zp0cl - ace2 - user manual page - 43/85 the contactor will be closed with 70% of battery voltage applied to the coil and then the voltage will be reduced to 49% of battery voltage. 15) aux output v rid it specifies the percentage of aux out volt parameter, supplied to eb coil to keep the electro ...

  • Page 44

    Page - 44/85 af2zp0cl - ace2 - user manual submenu "special adjust" 1) adjustment#01 reserved. 2) adjustment#02 reserved. 3) set current it adjust the regolation of maximum current. It shouldn’t be changed. 4) high adress reserved. 5) debug mode reserved. 6) inverter type it decides what kind of inv...

  • Page 45

    Af2zp0cl - ace2 - user manual page - 45/85 flow chart showing how to make changes to option menu. 1) opening zapi menu. Ae2t2b zp0.12 24v 400a 00000 2) press top left & right buttons to enter set menu. % ' % ' ' ' 3) the display will show: set model. Config menu set model 4) press roll up or roll do...

  • Page 46

    Page - 46/85 af2zp0cl - ace2 - user manual flow chart showing how to make changes to adjustments menu. 1) opening zapi menu. Ae2t2b zp0.12 24v 400a 00000 2) press top left & right buttons to enter config menu. % ' % ' ' ' 3) the display will show: set model. Config menu set model 4) press roll up or...

  • Page 47

    Af2zp0cl - ace2 - user manual page - 47/85 flow chart showing how to use the set battery type adjustment. 1) opening zapi menu. Ae2t2b zp0.12 24v 400a 00000 2) press top left & right buttons to enter config menu. % ' % ' ' ' 3) the display will show: set model. Config menu set model 4) press roll up...

  • Page 48

    Page - 48/85 af2zp0cl - ace2 - user manual flow chart showing how to carry out adjustment battery operation by console. 1) opening zapi menu. Ae2t2b zp0.12 24v 400a 00000 2) press top left & right buttons to enter config menu. % ' % ' ' ' 3) the display will show: set model. Config menu set model 4)...

  • Page 49: 8.5 Parameter  Regulation

    Af2zp0cl - ace2 - user manual page - 49/85 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 ca...

  • Page 50

    Page - 50/85 af2zp0cl - ace2 - user manual 9) release braking seconds. It controls the deceleration ramp when the travel request is released. The parameter sets the time needed to decelerate the traction motor from 100hz to 0hz. 10) inversion braking seconds. It controls the deceleration ramp when t...

  • Page 51

    Af2zp0cl - ace2 - user manual page - 51/85 17) cutback speed 1 speed reduction when the cutback input is active. 18) backing speed it determines the speed in inching function. 19) backing time it determines the time of the inching function. 20) frequency creep minimum speed when the forward or rever...

  • Page 52

    Page - 52/85 af2zp0cl - ace2 - user manual max speed fw hz 5 200 1 max speed bw hz 5 200 1 cutback speed 1 %max sp 10 100 1 frequency creep hz 0,6 4 0,1 maximum current % imax 0 100 1 brk smooth num 1 5 0,1 stop brk smooth hz. 3 20 1 auxiliary time sec. 0 10 0,1 4 (*) the acceleration time shown is ...

  • Page 53

    Af2zp0cl - ace2 - user manual page - 53/85 acceleration 1 parameter. 6) acc prof. Freq 2 in correspondence to this frequency in [hz] the acceleration is defined by the acceleration 2 parameter. 7) acc prof. Freq 3 in correspondence to this frequency in [hz] the acceleration is defined by the acceler...

  • Page 54

    Page - 54/85 af2zp0cl - ace2 - user manual minimum speed when the lift enable switch is closed, but the accelerator is on a minimum position. 16) maximum current this parameter changes the maximum current of the inverter. 17) auxiliary time time units value (seconds). For the encoder version, is the...

  • Page 55

    Af2zp0cl - ace2 - user manual page - 55/85 flow chart showing how to make programme changes using digital console fitted with eprom ck ultra. 1) opening 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 ch...

  • Page 56

    Page - 56/85 af2zp0cl - ace2 - user manual 8.6 programming console functions - functional configuration (see 8.1, 8.2, 8.3, 8.4). - parameter programming (see 8.5.1, 8.5.2). - tester: the user can verify the state of the following parameters: traction pump battery voltage (v) battery voltage (v) mot...

  • Page 57

    Af2zp0cl - ace2 - user manual page - 57/85 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 se...

  • Page 58

    Page - 58/85 af2zp0cl - ace2 - user manual 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 sequen...

  • Page 59

    Af2zp0cl - ace2 - user manual page - 59/85 8.9 tester: description of the function the most important input or output signals can be measured in real time using the tester function of the console. The console acts as a multimeter able to read voltage, current and temperature. The following definitio...

  • Page 60

    Page - 60/85 af2zp0cl - ace2 - user manual 16) cutback switch the level of the speed reduction microswitch. - on / gnd = active entry of speed reduction microswitch. - off / +vb = non active entry of microswitch. 17) hand brake the level of the hand brake microswitch. - on / gnd = active entry of br...

  • Page 61

    Af2zp0cl - ace2 - user manual page - 61/85 - on / +vb = active entry of closed switch. - off / gnd = non active entry of open switch. 15) 1st speed switch status of the first speed switch of the pump. - on / +vb = active entry of closed switch. - off / gnd = non active entry of open switch. 16) 2nd ...

  • Page 62

    Page - 62/85 af2zp0cl - ace2 - user manual flow chart showing how to use the tester 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 show: main menu parameter change 4) press roll up or ...

  • Page 63

    Af2zp0cl - ace2 - user manual page - 63/85 8.10 description of the console “save” function the save function allows the operator to transmit the parameter values and configuration data of the inverter into the console memory. It is possible to load 64 different programmes. The information saved in t...

  • Page 64

    Page - 64/85 af2zp0cl - ace2 - user manual 8.11 description of console “restore” function the restore param function allows transfer of the console’s stored data into the memory of the inverter. This is achieved in a fast and easy way using the method previously used with the save param. Function. T...

  • Page 65

    Af2zp0cl - ace2 - user manual page - 65/85 12) you can see the items that are being stored in the inverter memory whilst the restore routine is happening. Storing acceler. Delay 13) when finished the console displays: main menu restore param. 14) press out to return to the opening zapi display. ' ' ...

  • Page 66

    Page - 66/85 af2zp0cl - ace2 - user manual flow chart showing how to use the program vacc function of the digital console. 1) opening zapi display. Ac2 zapi v0.0 48v 350a 00000 2) press enter to go into the general menu. ' % ' ' ' ' 3) the display will show: main menu parameter change 4) press roll ...

  • Page 67

    Af2zp0cl - ace2 - user manual page - 67/85 8.13 description of the battery charge detection setting the battery charge detection uses two setting that specify the full charge voltage level (100%) and the discharge voltage level (10%). These two settings are the bat.Max.Adj and the bat.Min.Adj. It is...

  • Page 68

    Page - 68/85 af2zp0cl - ace2 - user manual 8.14 description of “alarms” menu the alarms logbook in the main menu’ records the alarms of the controller. It has a fifo (first input first output) structure that means the oldest alarm is lost when the database is full and a new alarm occurs. The logbook...

  • Page 69

    Af2zp0cl - ace2 - user manual page - 69/85 flow chart showing how to use the alarms function via 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 show: main menu parameter change 4) press roll up or...

  • Page 70

    Page - 70/85 af2zp0cl - ace2 - user manual warnings: these are faults which do not stop the truck or stop it by a controlled regenerative braking. In other words, the controller is working well, but it has detected conditions to reduce the performances or to stop the truck without opening the power ...

  • Page 71

    Af2zp0cl - ace2 - user manual page - 71/85 safety out the safety-out driver is damaged (shorted or open) mc is not closed, eb is applied, traction/pump stopped start-up traction/pump request watchdog#1 mdi code allarm 8 the watchdog signal #1 is not in the correct status mc is opened, eb is applied,...

  • Page 72

    Page - 72/85 af2zp0cl - ace2 - user manual hardware fault 20 the mosfets driver are not switched off with watch-dog signal in alarm status mc is not closed , eb is applied, traction/pump stopped start-up key re-cycle hardware fault 21 the eb/aux driver is not switched off with watch-dog signal in al...

  • Page 73

    Af2zp0cl - ace2 - user manual page - 73/85 8.17 analysis and troubleshooting of alarms displayed on console 1) flash checksum cause: after key-on the software verifies the integrity of program stored in the flash memory, if the verify has a negative result this alarm is generated. Troubleshooting: t...

  • Page 74

    Page - 74/85 af2zp0cl - ace2 - user manual cause: when the key is switched on, the inverter tries to charge the power capacitors through a series of a ptc and a power resistance, and check if the capacitor are charged within a timeout. If the capacitor voltage measured is less than 20% of the nomina...

  • Page 75

    Af2zp0cl - ace2 - user manual page - 75/85 the safety out driver is shorted. Troubleshooting: - check if there is a short or a low impedance pull-down between safety out (can#19) and –batt. - the driver circuit is damaged in the logic board, which has to be replaced. 10) watchdog#1 cause: at start-u...

  • Page 76

    Page - 76/85 af2zp0cl - ace2 - user manual and negative, to mc and to controller +batt and –batt, which must be screwed with a torque comprised in the range 13nm÷15nm. - if no voltage transient is detected on the supply line and the alarm is present every time the key is switched on, the failure is ...

  • Page 77

    Af2zp0cl - ace2 - user manual page - 77/85 17) vmn low cause 1: start-up test. Before switching the lc on, the software checks the power bridge: it turns on alternatingly the high side power mosfets and expects the phases voltage to increase toward the rail capacitor value. If the phases voltage is ...

  • Page 78

    Page - 78/85 af2zp0cl - ace2 - user manual 21) hardware fault 20 cause: before driving the mc coil, the controller checks if the mosfets drivers are turned of by a not active (alarm status) watch-dog signal. If they are not turned of then the alarm is generated. Troubleshooting: the problem is insid...

  • Page 79

    Af2zp0cl - ace2 - user manual page - 79/85 troubleshooting: - it could be a problem of the contacts in the mc that are not working (does not pull-in), try replacing the mc. - if the contactors of mc are working correctly than the problem is in the controller, replace it. 27) logic failure #2 cause: ...

  • Page 80

    Page - 80/85 af2zp0cl - ace2 - user manual 8.18 microcontroller warning overview error code description effect machine status when the test is done restart procedure vacc not ok mdi code allarm 78 the accelerator/ lift potentiometer value is higher than the minimum value recorded, and the direction/...

  • Page 81: Console

    Af2zp0cl - ace2 - user manual page - 81/85 8.19 analysis and troubleshooting of warnings displayed on console 1) vacc not ok cause: the test is made at key-on and immediately after that both the travel demands have been turned off. This alarm occurs if the accelerator reading in the tester menu’ is ...

  • Page 82

    Page - 82/85 af2zp0cl - ace2 - user manual 5) motor temperature cause: this warning occurs when the temperature sensor is opened (if digital) or has overtaken the threshold of 150° (if analogue). Troubleshooting: check the thermal sensor inside the motor (use the motor temperature reading in the tes...

  • Page 83

    Af2zp0cl - ace2 - user manual page - 83/85 11) slip profile cause: there is an error on the choice of the parameters of the slip profile. Troubleshooting: check in the hardware setting menu the value of those parameter 12) eeprom ko cause: it’s due to a hw or sw defect of the non-volatile embedded m...

  • Page 84: Inverter

    Page - 84/85 af2zp0cl - ace2 - user manual 9 recommended spare parts for inverter part number description ace version c16588 protected 350 a strip ul fuse. 24v/400 & 36-48v/450 c16588 protected 350 a strip ul fuse. 24v/500 c16586 protected 250 a strip ul fuse. 36-48v/350 c16603 protected 200 a strip...

  • Page 85

    Af2zp0cl - ace2 - user manual page - 85/85 10 periodic maintenance to be repeated at times indicated check the wear and condition of the contactors’ moving and fixed contacts. Electrical contacts should be checked every 3 months. Check the foot pedal or tiller microswitch. Using a suitable test mete...