Home

ACE2 INVERTER - ETP Kraftelektronik AB

1. 14 5 5 X M8 Male Screw 47 47 Existing others versions with or without power fuse With heat sink 200x40x185mm transversal With heat sink 200x40x200mm transversal longitudinal AF2ZPOCL ACE2 User Manual Page 27 85 7 3 Connection drawing Traction configuration I 5 w w a FLASH PROGRAMMING L 6 3 BATT TRACTION MOTOR ERY BATT BATT A22A23 Al4 A7 MS AB v Alo KE A4Q rw FH aso REV A SAFETY IN AIIQ o AG SEAT a HB SR 413 QA PPOTG12 5V gt gt De CPOT gt BATT gt DWA Aigo CPOTBR PLC PAUX Al7 a16 amp NLC A migo IX COI aro SAFETY DUT A200 CAN CAN I A210 ateo CAN T BRAKE POTI WING IS A TIVE TO THE ZAPI PRODUCTS PERTY ITS REPRODUCTION IS PROHIBITED EXCEPT FOR A WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS ACE2 TRACTION STANDALONE FUNCTIONAL DRAW Tecnico Technician FF HE 07 p 05 07 Visto Visa Page 28 85 Disegno n Drawing n Pagina Pa AF2ZP1AD AF2ZPOCL ACE2 User Manual 7 4Connection drawing Pump configuration
2. Q 2 3 4 a 6 NG 8 a A B B 31 ob Be apo KEY a B3 G LIFT ENABLE l Bi mo oo 454 SPEED Lal Q B5 B6 FLASH PROGRAMMING H B7 ao SAFETY IN NS Hapi ere Ge A6 SE A a130 SPEED3 A o D Fr q El PPUTCH12 5V a Ae 7 43 CPOT El LI EN 3 lt P ago BAIT sa al E pon v E MC to E SE SPEED a ato 6 SPEED2 pO a F E A lt E _ a17 O PLEZPEB Aig pp NC aay NE LC COIL s GON o a AUX COIL G g y G aig d SAFETY LU L FAN aeoo FAN L Fi A21Q CAN mpd CAN 1 H A2PAP3 Al4 A7 AIS AB 9 0 6 gt 2 S I In LI a gt n J THIS DRAWING IS A ZAPI s p a PROPERTY ITS RODUCTION IS PROHIBITED EXCEPT FOR A WRITTEN AUTHORIZATION THE ONLY ALLOWED USE IS THAT RELATIVE O THE REPAIRS OF Z PRODUCTS ACE2 PUMP STANDALONE FUNCTIONA DRAWING Data Date Tecnico Technician FF Visto Visa Serie Series AG AS Disegno n Drawing n AF2ZP1BA Pagina Page AF2ZPOCL ACE2 User Manual Page 29 85 7 5 Connection drawing Combi configuration 0 1 2 3 4 3 6 7 8 g f A 1 a KE O BI BF O B2 Ap p 7 rv Be TRA CONSOLE Lo Aso LO B4 ap SAFETY IN 5 I B AG SEA L Aigo ESE Po E OB PPOT 12 5V gt ON l Ae se a o o O BB CPOT 9 PA SE 3 ak BATT Y a va A9 C ho Ti oa TRACTION a La gt ato CPOTER E gt
3. Procedure is detailed on Chapter 9 4 5 Set the MAXIMUM CURRENT Current using the table on Chapter 8 5 2 6 Set the Acceleration and Deceleration Delay requirements for the pump 7 Set the FREQUENCY CREEP level starting from O Hz The pump should just turn when the request microswitch is closed Increase the level accordingly 8 Set the Speed Reductions as required Make adjustments to CUTBACK SPEED 1 Check the performance with the full request Check the performance with and without load 9 Set MAX SPEED LIFT max speed of pump motor when Lift enable switch is closed 10 Set 1ST SPEED COARSE speed of pump motor when SPEED1 switch is closed 11 Set 2ND SPEED COARSE speed of pump motor when SPEED switch is closed 12 Set 3RD SPEED COARSE speed of pump motor when SPEEDS switch is closed 13 Set HYD SPEED FINE to adjust the hydraulic steering speed pump motor speed when HYDRO function is requested 14 Set AUXILIARY TIME time delay before pump stops when an hydraulic steering function request is switched off 15 Set SET TEMPERATURE setting the motor thermal sensor type used AF2ZPOCL ACE2 User Manual 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 definit
4. FREQUENCY Hz ADJUSTMENTS ENCODER Hz SLIP VALUE Hz CURRENT RMS A OTOR POWER W BATTERY CHARGE TEMPERATURE E OTOR TEMPERATURE C HANDLE SEAT SW ON OFF LIFTING CONTROL V LIFTING SWITCH ON OFF SLS D SWITCH ON OFF 2 ND SPEED SWITCH ON OFF 3 RD SPEED SWITCH ON OFI HYDRO SPEED REQ ON OFF CUTBACK SWITCH ON OFF 2ND HOURMETERS SAVE PARAMETER RESTORE PARAMETER CODE ALARMS h NG C PROGRAM VACC VACC SETTING MIN MAX MOTOR DATA NOT AVAILABLE AF2ZPOCL ACE2 User Manual SET BATTERY TYPE ADJUST BATTERY V THROTTLE O ZONE THROTTLE X ZONE THROTTLE Y ZONE BAT MIN ADJ 0 9 BAT MAX ADJ 0 9 ADJUSTMENT 03 0 9 LOAD HM FROM MDI ON OFF CHECK UP DONE ON OFF CHECK UP TYPE MAIN CONT VOLT AUX OUTPUT VOLT MAIN CONT V RID AUX OUTPUT V RID Page 33 85 3 4 Function configuration 8 4 1 Traction Page 34 85 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 DISPLAY TYPE This parameter decides wich display is connected to the inverter 0 No Display 1 MDI PRC connected 2 ECO DISPLAY connected 3 SMART DISPLAY connected 4 MDI CAN connected 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 whe
5. Contents MODIG ON ee 5 SPECIRGATION antenne 6 2 1 Technical specifications AGE ninia dica 6 2 2 Technical specifications ACE2 Power ranannnvnnnnnnnnvennnnnnnvnnnnnnnnrrnnnnnnrrrnennrnnnrrennennnnnne 6 223 Block dia AM cedidas acido e daj EE ads alisios ts 7 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 8 3 1 Microswitches EE EE ei pe a NE EEE 8 3 2 Feberen 8 3 3 Other analog control Uni maapakan AA 9 3 4 Speed pis cate APM A 10 INSTALLATION HINTS SE 11 4 1 Material OVervieW RE EE Aa 11 4 1 1 Connection cables aaa note video ta s 11 4 1 2 e Ae PA denie 11 213 PES See 11 4 2 Installation of the hardware ssrrrrrnnnonvrrnnnnnnnvrnnnnnnnvrnnnnnnnrnnnenrnrrnnnnerrrrrnnerrnnrrnesennnnn 12 4 2 1 Positioning and cooling of the controller rarnnvrrnrnrnnnrnnnnrnnnrnnnrrvnnrnnnnernnr 12 422 Wirings power Cables v akan kme 12 4 2 3 Wirings CAN connections and possible interferences ereeeerrroes 13 4 2 4 Wirings WO CONNECTIONS eect ee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeseaaeeeeessaaeeees 15 4 2 5 Connection of the encoder rrrrrrnnnnrnrrrnnnnvnnrrnnnannnnrennnnnnnnnnnnrnnarnnnnnrnrnnnsenne 15 4 2 6 Main contactor and key connection ooooocononccccnnccccccnnnncannnnonononnnnnnnarnncncnnnnnns 16 4 2 7 Insulation of truck frame aaanwawwaannnanaawananaaasaasanasaaananananaannansaaaasansanann 16 4 3 Protection and safety features ooonnocc
6. The level of the Handle Seat digital entry ON GND active entry of closed switch OFF GND non active entry of open switch 14 FORWARD SWITCH The level of the Forward direction digital entry FW ON VB active entry of closed switch OFF GND non active entry of open switch 15 BACKWARD SWITCH The level of the Reverse direction digital entry BW ON VB active entry of closed switch OFF GND non active entry of open switch AF2ZPOCL ACE2 User Manual Page 59 85 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 Brake pedal Microswitch OFF VB non active entry of microswitch 18 BRAKEPEDAL POT The percentage of the pressure on the brake pedal 100 if the pedal is totally pressed 0 if the pedal is released 19 2ND HOURMETERS This parameter displays the working hour of traction controller 20 STEER ANGLE It shows the steering angle 8 9 2 Pump 1 BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch 2 MOTOR VOLTAGE This is the voltage supplied to the motor by the inverter it is expressed as a percentage of the full voltage which depends of the battery voltage 3 VOLTAGE BOOSTER This is the booster of the voltage supplied to the motor in load condition i
7. accelerator pedal and press the Pedal Brake Set braking level to your requirements If the machine is a forklift check the performance with and without load 13 SPEED LIMIT BRAKING If used Operate the machine at full Speed Close the speed reduction switch Set braking level to your requirements If the machine is a forklift check the performance with and without load 14 Set MAX SPEED FORW 15 Set MAX SPEED BACK Reverse 16 Make the choice for the truck behaviour on a slope see chapter 8 4 If the Stop on ramp option is ON set the desired value of auxiliary time parameter 17 Set SET TEMPERATURE setting the motor thermal sensor type used AF2ZPOCL ACE2 User Manual Page 57 85 8 8 Sequence for Ac Inverter Pump setting Page 58 85 When the Key Switch is closed if no alarms or errors are present the Console Display will be showing the Standard Zapi Opening Display If the controller is not configured to your requirements follow the sequence detailed on Chapter 9 2 Remember to re cycle the Key Switch if you make any changes to the controller s configuration Otherwise follow the sequence detailed below 1 Select the Options required See Chapter 8 4 2 2 Select and set the Battery Voltage See Chapter 8 4 2 3 Confirm correct installation of all wires Use the Console s TESTER function to assist 4 Perform the lift signal acquisition procedure using the Console PROGRAM VACC
8. the procedure is similar to the Program Vacc function see chapter 9 4 This procedure must be carried out only if the Pedal braking option is programmed as Analog 3 SET BATTERY TYPE It selects the nominal battery voltage 4 ADJUST BATTERY Fine adjustment of the battery voltage measured by the controller AF2ZPOCL ACE2 User Manual Page 35 85 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 of the accelerator input curve A VACC MIN and VACC MAX are values programmable by the Program Vacc function 8 BATT MIN ADJ It adjusts the lower level of the battery discharge table It is used to calibrate the discharge algorithm with the battery of the application See chapter 9 5 for more information 9 BATT MAX ADJ It adjusts the upper level of the battery discharge table It is used to calibrate the discharge algorithm with the battery of the application See chapter 9 5 for more information 10 ADJUSTMENT 03 This parameter adjusts the updating of battery charge after Key On Decreasing this parameter the difference between the battery voltage measured after Key On and the last stored value necessary to update the charge with the new value measured decrease It is used to calibrate t
9. Effect Machine status Restart Code When the test is procedure done Flash checksum The program verify MC is not closed Start up Key re cycle MDI code allarm 71 is EB is applied not OK traction pump stopped Analog The analogue MC is opened Start up running Traction Pump MDI code allarm 96 Channel EB is applied request Reading is not traction pump updated stopped Wrong set battery The absolute MC is not closed Start up Traction Pump difference between EB is applied Request the Key voltage and traction pump the nominal battery stopped voltage is greater than 20 of Vbatt nom Capacitor charge Power capacitors MC is not closed Start up Traction Pump MDI code allarm 60 Voltage does not EB is applied request Increase Traction Pump stopped Coil shorted hw ko The harware to MC is not closed Start up Traction Pump MDI code allarm 76 check a MC or EB is applied Request EB AUX coil Traction Pump shorted is damaged stopped Driver shorted The MC driver is MC is opened the Start up stand by Traction Pump MDI code allarm 74 shorted so it is not command is running Request able to open the released EB is contactor applied Traction Pump stopped Aux driver shorted The EB AUX driver MC is opened the Start up stand by Traction Pump is shorted so it is command is running Request not able to open the released EB is contactor applied Traction Pump stopped Safety in The safety inputis MC is opened Star
10. THE INSTALLATION KIT The ACE2 inverter needs some external parts in order to work The following devices complete the kit for the ACE2 installation fa Microswitches The microswitches must have a contact resistance lower than 0 1 Q and a leakage current lower than 100 pA When full load connected the voltage drop between the key switch contacts must be lower than 0 1 V The microswitches send a voltage signal to the microprocessor when a function request for ex running request is made 3 2 Accelerator unit Page 8 85 The accelerator unit can consist of a potentiometer or an Hall effect device It should be in a 3 wire configuration The potentiometer is supplied through CNA 2 Potentiometer output signal must be input to CPOT CNAt3 signal range is from Oto 10 V The negative supply of the potentiometer has to be taken from CNA 9 GND or from CNA 5 REV 1ST SPEED if the diagnosis PEDAL WIRE KO is done In this case the hardware must be configured closing a jumper on the logic card Potentiometer value should be in the 0 5 10 kQ range generally the load should be in the 1 5 mA to 30 mA range Faults can occur if it is outside this range The standard connection for the potentiometer is the one in the Left side of next figure potentiometer on one end at rest in combination with a couple of Travel demand switches On request it is also possible the handling in the Right side of next figure potentiom
11. The contactor will be closed with 70 of battery voltage applied to the coil and then the voltage will be kept at the same value Example 3 MAIN CONT VOLTAGE 70 MAIN CONT V RID 70 AF2ZPOCL ACE2 User Manual 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 mechanic brake applied Example 1 MAIN CONT VOLTAGE 100 MAIN CONT V RID 70 The load will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70 of battery voltage Example 2 MAIN CONT VOLTAGE 70 MAIN CONT V RID 100 The load will be closed with 70 of battery voltage applied to the coil and then the voltage will be kept at the same value Example 3 MAIN CONT VOLTAGE 70 MAIN CONT V RID 70 The load will be closed with 70 of battery voltage applied to the coil and then the voltage will be reduced to 49 of battery voltage AF2ZPOCL ACE2 User Manual Page 43 85 SUBMENU SPECIAL ADJUST 1 2 ADJUSTMENT 01 Reserved ADJUSTMENT 02 Reserved SET CURRENT It adjust the regolation of maximum current It shouldn t be changed HIGH ADRESS Reserved DEBUG MODE Reserved INVERTER TYPE It decides what kind of inverter is used 0 and 1 traction 2 and 3 pump The change of this pa
12. Y a La Li a 8 Lu IR EE L IT E a SAFETY DUT lt D mM ks la yi as m E F ai a KEY A T ENAB ago HET ENABLE genou PEEDI SPEED A b _ SAFETY IN 4 B6 All O 0 FLASH PROGRAMMING p7 ago SEA Ni SPEED3 L AN dwan pigo SPEEDS y nab PPOTGH2 5V 5 sa CPOT a LI A30 PUMP BATT IE A9 pi PUMP a e ee METER 2176 PLC PEB w A17 A A NLC a A a A16 P T sigo NEB Bi g l DIL2 m DUT I Li ION THE ONLY AL Pagina P Page 30 85 AF2ZPOCL ACE2 User Manual 8 PROGRAMMING amp 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 e Description of Console 8 Connection E NVERTER NNN NN NN SN y Is BIL SAU NN AA kak MAA AA D N NN N A N N DISPLAY 1 PARAM IMAX B REVERSE BRAKING COMPENS ACCEL R BRAKE Ev TESTER MAX SP SPEED I F S P I SPEED II 3 SAVE S P I SPEED Il BYPASS FIELD WEAK 4 RESTORE MOT ver A
13. backward switch ON OFF 1 speed switch ON OFF cutback switch ON OFF 2 speed switch ON OFF hand brake ON OFF 3 4 speed switch ON OFF Brakepedal pot hydro speed req ON OFF 2 hourmeters 2 hourmeters Save function for storing data Restore function for loading parameters on another inverter Display of the last 5 alarms including hour meter value and temperature at the moment of the alarm Accelerator range programming records the minimum and maximum useful accelerator stroke values for both direction of running See the console manual for a detailed description of function and parameters Page 56 85 AF2ZPOCL ACE2 User Manual 8 7 Sequence for Ac Inverter Traction setting When the Key Switch is closed if no alarms or errors are present the Console Display will be showing the Standard Zapi Opening Display If the controller is not configured to your requirements follow the sequence detailed on Chapter 9 2 Remember to re cycle the Key Switch if you make any changes to the controller s configuration Otherwise follow the sequence detailed below 1 Select the Options required See Chapter 8 4 1 2 Select and set the Battery Voltage See Chapter 8 4 1 3 Confirm correct installation of all wires Use the Console s TESTER function to assist 4 Perform the accelerator signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on Chapte
14. devices on a daily basis for correct functioning this precaution is particularly important during controller handling in the storing and installation phase ISOLATION use anti static containers when transferring ESD sensitive material GROUNDING when a complete isolation cannot be achieved a good grounding can divert the discharge current trough a safe path the frame of a truck can works like a local earth ground absorbing excess charge So it is strongly suggested to connect to truck frame all the parts of the truck which can be touched by the operator who is most of the AF2ZPOCL ACE2 User Manual Page 19 85 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 lift for ex they must belong to the ZAPIMOS family During battery charge disconnect ASYNCHRONOUS from the battery Page 20 85 AF2ZPOCL ACE2 User Manual 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 regenerative braking if the speed overtakes the speed set point the system can perform an electrical stop on a ramp the machi
15. temperature can never exceed 105 C External agents The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP65 Protection against uncontrolled movements The main contactor will not close if The Power unit is not functioning The Logic is not functioning perfectly The output voltage of the accelerator does not fall below the minimum voltage value stored with 1 V added Running microswitch in closed position Low battery charge When the battery charge is low the maximum current is reduced to the half of the maximum current programmed Protection against accidental Start up A precise sequence of operations are necessary before the machine will start Operation cannot begin if these operations are not carried out correctly Requests for drive must be made after closing the key switch 4 3 2 Safety Features A ZAPI controllers are designed according to the prEN954 1 specifications for safety related parts of control system and to UNI EN1175 1 norm The safety of the machine is strongly related to installation length layout and screening of electrical connections have to be carefully designed ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions Furthermore ZAPI is available to develop new SW or HW solutions to improve the safety of the machine according to customer requirements Machine manufacturer holds t
16. the 120 Ohm termination resistance between CAN L and CAN H Speed reduction handbrake input Active with switch opened Not active with switch closed to Batt Incremental encoder phase B input Encoder negative power supply Main contactor coil output The coil is driven to negative reference Positive of the main contactor and electromechanical brake coil Electro mechanic brake coil output The coil is driven to negative reference It drives the external load to negative reference when the REV input is active It can be used for a flashing light or acoustic indicator The maximum current load is 1 A In case of inductive load it is suggested to use a free wheeling diode across the load with cathode Page 23 85 A20 A21 A22 A23 B1 B2 B3 B4 B5 B6 B7 B8 CAN L CAN H PTHERM NTHERM PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH FLASH connected to Batt Low level CAN BUS voltage I O High level CAN BUS voltage I O Input for motor temperature sensor It is possible to use a digital or analogue PTC sensor Batt Positive serial reception Not used it can be disconnected Negative serial reception Positive serial transmission Negative serial transmission Negative console power supply Positive console power supply It must be connected to B8 for the Flash memory programming It must be connected to B7 for the Flash memory programming 6 2 Connectors of the logic Pum
17. the motor acceleration at ACC PROF FREQ 2 Hz At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases ACCELERATION 3 It specifies the motor acceleration at ACC PROF FREQ 3 Hz At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases ACC PROF FREQ 1 In correspondence to this frequency in Hz the acceleration is defined by the ACCELERATION 1 parameter ACC PROF FREQ 2 In correspondence to this frequency in Hz the acceleration is defined by the ACCELERATION 2 parameter ACC PROF FREQ 3 In correspondence to this frequency in Hz the acceleration is defined by the ACCELERATION 3 parameter AF2ZPOCL ACE2 User Manual Page 49 85 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 OHz 10 INVERSION BRAKING Seconds It controls the deceleration ramp when the direction switch is inverted during travel The parameter sets the time needed to decelerate the traction motor from 100Hz to OHz 11 DECELERATION BRAKING Seconds It controls the deceleration ramp when the accelerator has turned down but not completely released The parameter sets the time needed to decelerate the traction motor from 100Hz to OHZ 12 PEDAL BRAKING Seconds It controls the deceleration ramp when the pedal positi
18. voltage measured with a voltmeter If it does not match then do an ADJUST BATTERY function Replace the battery 4 CAPACITOR CHARGE Follows the charging capacitor system AF2ZPOCL ACE2 User Manual Page 73 85 Page 74 85 9 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 nominal battery voltage an alarm is signalled the main contactor is not closed Troubleshooting There is an external load in parallel to capacitor bank which sinks current from the controller capacitors pre charging circuit thus preventing the caps from charging Check if a lamp or a dc dc converter or an auxiliary load is placed in parallel to capacitor bank The charging resistance or PTC is opened insert a power resistance across line contactor power terminals if the alarm disappears it means the controller internal charging resistance is damaged The charging circuit has a failure inside the controller There is a problem in the controller power section COIL SHORT HW KO Cause The hardware circuits which manages short circuits protection of LC and EB AUX coils has a problem Troubleshooting This type of fault is not related to external components replace the ACE logic board DRIVER SHORTED Cause The dri
19. AN H PTHERM NTHERM PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH FLASH connected to Batt Incremental encoder phase B input Encoder negative power supply Main contactor coil output The coil is driven to negative reference Positive of the LC and Auxiliary coil Auxiliary coil output The coil is driven to negative reference In the COMBI configuration it is connected to SAFETY IN CNA 11 of traction controller It can also be used to drive an external load to negative reference when the pump motor is driven The maximum current load is 1 A In case of inductive load it is suggested to use a free wheeling diode across the load with cathode connected to Batt Low level CAN BUS voltage I O High level CAN BUS voltage I O Input for motor temperature sensor It is possible to use a digital or analogue PTC sensor Batt Positive serial reception Not used it can be disconnected Negative serial reception Positive serial transmission Negative serial transmission Negative console power supply Positive console power supply It must be connected to B8 for the Flash memory programming It must be connected to B7 for the Flash memory programming e Description of power connections View of the power bars BATT BATT U V W AF2ZP0CL ACE2 User Manual Negative of the battery Positive of the battery Connection bars of the three motor phases follow this sequence and the indica
20. ANCE 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 meter confirm that there is no electrical resistance between the contacts by measuring the volt drop between the terminals Switches should operate with a firm click sound Microswitches should be checked every 3 months Check the Battery cables cables to the inverter and cables to the motor Ensure the insulation is sound and the connections are tight Cables should be checked every 3 months Check the mechanical operation of the pedal or tiller Are the return springs ok Do the potentiometers wind up to their full or programmed level Check every 3 months Check the mechanical operation of the Contactor s Moving contacts should be free to move without restriction Check every 3 months Checks should be carried out by qualified personnel and any replacement parts used should be original Beware of NON ORIGINAL PARTS The installation of this electronic controller should be made according to the diagrams included in this Manual Any variations or special requirements should be made after consulting a Zapi Agent The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual During periodic checks if a technician finds any situa
21. B AUX driver is turned of by a not active alarm status Watch dog signal If it is not turned of then the alarm is generated Troubleshooting The problem is inside the controller no external component are involved replace the logic board 23 HARDWARE FAULT A1 Cause Before driving the MC coil the controller checks if the MC AUX driver is turned of by a not active alarm status Watch dog signal If it is not turned of then the alarm is generated Troubleshooting The problem is inside the controller no external component are involved replace the logic board 24 COIL SHORTED MC Cause This alarm occurs when there is a short circuit of the MC coils connected to CNA 16 output After the overload condition has been removed the alarm exits automatically by releasing and then enabling a travel demand Troubleshooting The typical root cause for this error code to be displayed is in the harness or in the load coil So the very first check to carry out concerns connections between controller outputs and loads Incase no failures problems have been found externally the problem is in the controller which has to be replaced 25 COIL SHORTED EF Cause This alarm occurs when there is a short circuit of the EB AUX coils connected to CNA 18 output After the overload condition has been removed the alarm exits automatically by releasing and then enabling a travel demand Troubleshooting The typical root cause for this
22. HROTTLE X ZONE FREQUENCY Hz THROTTLE Y ZONE ENCODER Hz BAT MIN ADJ SLIP VALUE Hz BAT MAX ADJ CURRENT RMS A ADJUSTMENT 03 OTOR POWER W LOAD HM FROM MDI BATTERY CHARGE CHECK UP DONE TEMPERATURE e CHECK UP TYPE MOTOR TEMPERATURE C AIN CONT VOLT ACCELERATOR v AUX OUTPUT VOLI HANDLE SEAT SW ON OFF AIN CONT V RID FORW SWITCH ON OFF AUX OUTPUT V RID BACK SWITCH ON OFF CUTBACK SWITCH ON OFF AND BRAKE ON OFF BRAKE PEDAL POT 2ND HOURMETERS SAVE PARAMETER RESTORE PARAMETER ne CODE LARMS h N C PROGRAM VACC VACC SETTING MIN MAX MOTOR DATA NOT AVAILABLE AF2ZPOCL ACE2 User Manual 8 3 2 Pump configuration CONNECTED O 02255 MLLER SWITCH HOUR COUNTER CUTBACK MODE BATTERY CHECK STOP AUX OUTPUT 1 ON SET MOT HANDLE SEAI ON OFF RAMP ON OFF TEMP RUNNING KEY ON PRESENT ABSENT HYDRO CONT BRAKE EXCL HYDRO ANALOG DIGITAL NONE HEADING MAIN MENU HAI maa ACCELERATIO 0 SET MODEL ACCELERATION 1 Se ACCELERATION 2 Sec ACCELERATION 3 Sec ACC PROF FREQ 1 z ACC PROF FREQ 2 Hz ACC PROF FREQ 3 Hz RELEASE Sec SET OPTIONS AX S Hz IST SPEED COARSE Hz 2ND COARSE Hz 3RD S COARSE Hz HYD SPEED FINE Hz CUTBACK SPEED 1 FREQUENCY CREEP z AXIMUM CURRENT AUXILIARY TIME Sec BATTERY VOLTAGE Vv TESTER OTOR VOLTAGE VOLTAGE BOOSTER
23. R Cause This fault is signalled in following conditions the frequency supplied to the motor is higher than 40 Hz and the signal feedback from the encoder has a jump higher than 40 Hz in few tens mSec This condition is related to a malfunctioning of the encoder Troubleshooting Check both the electric and the mechanical encoder functionality the wires crimping Check the encoder mechanical installation if the encoder slips inside its compartment raising this alarm condition Also the electromagnetic noise on the sensor bearing can be a cause for the alarm In these cases try to replace the encoder If the problem is still present after replacing the encoder the failure is in the controller 31 WRONG RAM MEMORY Cause The algorithm implemented to check the main RAM registers finds a wrong contents the register is dirty This alarm inhibit the machine operations Troubleshooting Try to switch the key off and then on if the alarm is still present replace the ACE2 logic board AF2ZPOCL ACE2 User Manual Page 79 85 fe 8 Microcontroller warning overview Error code Description Effect Machine status Restart when the testis procedure done Vacc not OK The accelerator lift Traction Pump motor Start up stand Traction Pump MDI code potentiometer value is higher is stopped by running request allarm 78 than the minimum value recorded and the direction enable switches are opened In
24. RE 14 Press ENTER for yes or OUT for NO 15 When finished the Console shows 16 Press OUT again to return to the Opening Zapi Menu AG2 ZAPI VO O 48V 350A 00000 DO DO MAIN E O D0 O MENU PARAMETER GHANGE MAIN MENU PROGRAM VAGG MIN VACC MAX 0 6 T 4 4 o bu omo ARE YOU SURE YES ENTER NO OUT DO DO Bo Bo MAIN MENU PROGRAM VAGG AF2ZPOCL ACE2 User Manual 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 possible to adapt the Battery Charge Detection to your specific battery by changing the above two settings e g if the Battery Discharged Detection occurs when the battery is not totally discharged it is necessary to reduce the Bat Min Adj setting as indicated in the figure below 48V NOMINAL BATTERY VOLTAGE a A 24V NOMINAL BATTERY VOLTAGE A AF2ZPOCL ACE2 User Manual Page 67 85 8 14Description of ALARMS menu Page 68 85 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 is composed of five locations getting possible to stack fiv
25. RM and A23 NTHERM are used for a motor thermal sensor It can be digital on off sensor normally closed or analog See also chapter 8 4 for more explanation AF2ZPOCL ACE2 User Manual Page 9 85 3 4Speed 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 collector NPN push pull standard A and B output For more details about encoder installation see also chapter 4 2 5 EY Note The encoder resolution and the motor poles pair the controller can handle is specified in the home page display of the handset showing following headline AE2T2B ZP1 13 That means AE2T ACE 2 traction controller AE2P ACE 2 pump controller 2 motor s poles pair number B 64 pulses rev encoder The encoder resolution is given by the last letter in the following list A 32 pulses rev B 64 pulses rev C 80 pulses rev D 128 pulses rev Page 10 85 AF2ZPOCL ACE2 User Manual 4 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colors they mean EY These are information useful for anyone is working on the installation or a deeper examination of the content A These are Warning boxes they describe operations that can lead to a failure of the electronic devic
26. Self diagnosis the faults can be displayed through the console or Zapi s MDI Display Modification of parameters through the programming console Internal hour meter with values that can be displayed on the console Memory of the last five alarms with relative hour meter and temperature displayed on the console Test function within console for checking main parameters AF2ZPOCL ACE2 User Manual Page 21 85 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 charging phase s voltages contactor drives can bus interface if the switch sequence for operation is correct and if the output of accelerator unit is correct 2 Standby diagnosis in standby that checks watchdog circuit phase s voltages contactor driver current sensor can bus interface 3 Diagnosis during operation that checks watchdog circuits contactor driver current sensors can bus interface 4 Continuous diagnosis that check temperature of the inverter motor temperature Diagnosis is provided in two ways The digital console can be used which gives a detailed information about the failure the failure code is also sent on the Can Bus Page 22 85 AF2ZPOCL ACE2 User Manual 6 DESCRIPTION OF THE CONNECTORS 6 1 Connectors of the
27. UT if you do not accept the changes 15 SET OPTIONS Menu appears 16 Press OUT again Display now show the Opening Zapi Menu AF2ZPOCL ACE2 User Manual AE2T2B ZPO 12 24V 400A 00000 Bod ood CONFIG MENU SET OPTIONS Deo BOO HOUR COUNTER RUNNING BOO BOO BATTERY CHECK OFF OO 00 BATTERY GHEGK ON ODO BO ARE YOU SURE YES ENTER NO OUT CONFIG MENU SET OPTIONS Page 45 85 Flow chart showing how to make changes to ADJUSTMENTS Menu AE2T2B ZPO 12 24V 400A 00000 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG OM Menu poo 3 The display will show SET MODEL ers 4 Press ROLL UP or ROLL DOWN button until mon ADJUSTMENTS Menu appears Dou 5 ADJUSTMENTS appears on the display ANE ME G 6 Press ENTER to go into the ADJUSTMENTS a Menu poo a BATTERY TYPE 7 The display will shows SET BATTERY TYPE KAY 8 Press ROLL UP or ROLL DOWN button until the mon desired parameter is reached mon 9 The desired parameter appears 10 Press SET UP or SET DOWN button to modify Dou the adjustment Dou TROTTLE O ZONE 7 11 Press OUT an 12 Press ENTER to confirm 5 o 13 Repeat the same from 5 to 12 points for the other adjustments Page 46 85 AF2ZPOCL ACE2 User Manual Flow chart showing how to use the SET BATTERY TYPE adjustment EO E ood 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to en
28. V A mann 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 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 held responsible to third parties for damage caused by the improper use of the present publication and of the device devices described in it Zapi spa reserves the right to make changes or improvements to its products at any time and without notice The present publication reflects the characteristics of the product described at the moment of distribution The publication therefore does not reflect any changes in the characteristics of the product as a result of updating VA MAP I is a registered trademark property of Zapi S p A NOTES LEGEND EY The symbol aboard is used inside this publication to indicate an annotation or a suggestion you should pay attention A The symbol aboard is used inside this publication to indicate an action or a characteristic very important as for security Pay special attention to the annotations pointed out with this symbol Page 2 85 AF2ZPOCL ACE2 User Manual N
29. a function of the load The braking feature is based upon deceleration ramps The value shown in the table is the time to decrease the speed from 100 Hz to 0 Hz This is the ideal ramps calculated by the software the real ramp could change as a function of motor control parameter setting and obviously as a function of the load After changing a parameter press ENTER to confirm data when requested by the message on the console Parameters modified and optimized on one unit can be stored by the console SAVE and then released RESTORE on another inverter thus allowing fast and standardized settings see console manual for details The following parameters can be modified 1 ACCELERATION 0 It specifies the motor acceleration at 0 Hz At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases 2 ACCELERATION 1 It specifies the motor acceleration at ACC PROF FREQ 1 Hz At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases 3 ACCELERATION 2 It specifies the motor acceleration at ACC PROF FREQ 2 Hz At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases 4 ACCELERATION 3 It specifies the motor acceleration at ACC PROF FREQ 3 Hz At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases 5 ACC PROF FREQ 1 In correspondence to this freque
30. afety input and open the power line in case of malfunctioning of traction controller 44 EMC A EMC and ESD performances of an electronic system are strongly influenced by the installation Special attention must be given to the lengths and the paths of the electric connections and the shields This situation is beyond ZAPI s control Zapi can offer assistance and suggestions based on its years experience on EMC related items However ZAPI declines 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 norms EN12895 for industrial truck EN50081 2 for other applications EMC stands for Electromagnetic Compatibility and it represents the studies and the tests on the electromagnetic energy generated or received by an electrical device So the analysis works in two directions 1 The study of the emission problems the disturbances generated by the device and the possible countermeasure to prevent the propagation of that energy we talk about conduction issues when guiding structures such as wires and cables are involved radiated emissions issues when it is studied the propagation of electromagnetic energy through the open space In our case the origin of the disturbances can be found inside the controller with the switching of the mosfets which are working at high frequency and genera
31. ain contactor can be carried out following the drawing in the figure aQ The connection of the battery line switches must be carried out following ZAPI instructions Ifa mechanical battery line switch is installed it is necessary that the key supply to the inverter is open together with power battery line if not the inverter may be damaged if the switch is opened during a regenerative braking An intrinsic protection is present inside the logic when the voltage on the battery power connection overtakes 40 more than the battery nominal voltage or if the key is switched off before the battery power line is disconnected 4 2 7 Insulation of truck frame A As stated by EN 1175 Safety of machinery Industrial truck chapter 5 7 there shall be no electrical connection to the truck frame So the truck frame has to be isolated from any electrical potential of the truck power line Page 16 85 AF2ZPOCL ACE2 User Manual fes 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 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 reduced in proportion to the thermal increase The
32. al acquisition of the potentiometer gt gt gt gt gt gt gt gt Y Y Z N G Y Zi i j Y 7 K ZA Y 3 f ZE Ze This function looks for and remembers the minimum and maximum potentiometer wiper voltage over the full mechanical range of the pedal It enables compensation for non symmetry of the mechanical system between directions The operation is performed by operating the pedal after entering the PROGRAM VACC function AF2ZPOCL ACE2 User Manual Page 65 85 Page 66 85 Flow Chart showing how to use the PROGRAM VACC function of the Digital Console 1 Opening Zapi Display 2 Press ENTER to go into the General Menu 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until PROGRAM VACC appears on the display 5 The Display will show 6 Press ENTER to go into the PROGRAM VACC routine 7 The Display will show the minimum and maximum values of potentiometer wiper output Both directions can be shown 8 Press ENTER to clear these values Display will show 0 0 9 Select Forward Direction close any interlock switches that may be in the system 10 Slowly depress the accelerator pedal or tiller butterfly to its maximum value The new minimum and maximum voltages will be displayed on the Console plus an arrow indicating the direction 11 Select the Reverse Direction and repeat Item 10 12 When finished press OUT 13 The Display will ask ARE YOU SU
33. arry critical information inthe worst case and when the amount of charge is very high the discharge process can determine failures in the electronic devices the type of failure can vary from an intermittently malfunction to a completely failure of the electronic device EY IMPORTANT NOTE it is always much easier and cheaper to avoid ESD from being generated than to increase the level of immunity of the electronic devices There are different solutions for EMC issues depending on level of emissions immunity required the type of controller materials and position of the wires and electronic components 1 EMISSIONS Three ways can be followed to reduce the emissions SOURCE OF EMISSIONS finding the main source of disturb and work on it SHIELDING enclosing contactor and controller in a shielded box using shielded cables LAYOUT a good layout of the cables can minimize the antenna effect cables running nearby the truck frame or in iron channels connected to truck frames is generally a suggested not expensive solution to reduce the emission level 2 ELECTROMAGNETIC IMMUNITY The considerations made for emissions are valid also for immunity Additionally further protection can be achieved with ferrite beads and bypass capacitors 3 ELECTROSTATIC IMMUNITY Three ways can be followed to prevent damages from ESD PREVENTION when handling ESD sensitive electronic parts ensure the operator is grounded test grounding
34. closed Start up Traction Pump voltage higher than EB is applied Stand by request expected Traction Pump stopped Vmn low Motor output MC is opened Start up running Traction Pump MDI code allarm 72 voltage lower than EB is applied request expected Traction Pump stopped Stby I high In stby condition MC is not closed Start up Traction Pump MDI code allarm 53 no current applied EB is applied request to the motor the Traction Pump current feedbacks stopped are out of permitted stby range Wrong 0 voltage The motor phases MC is not closed Start up Traction Pump MDI code allarm 53 voltage feedback EB is applied Request are out of permitted Traction Pump range stopped Contactor closed LG contact is stuck MC is not closed Start up Traction Pump MDI code allarm 75 command is not Request activated EB is applied Traction Pump stopped AF2ZPOCL ACE2 User Manual Page 71 85 Hardware fault 20 The Mosfets driver MC is not closed Start up Key re cycle are not switched off EB is applied with Watch dog Traction Pump signal in alarm stopped status Hardware fault 21 The EB AUX driver MC is not closed Start up Key re cycle is not switched off EB is applied with Watch dog Traction Pump signal in alarm stopped status Hardware fault A1 The MC driver is MC is not closed Start up Key re cycle not switched off EB is applied with Watch dog Traction Pump signal in a
35. cnninnnncccnnnnoncccccnnncncnccnonncnnnnne nn nn nnnnnn cc nn rnnnnnnncnnns 17 4 3 1 Protection Talks asistida as 17 4 3 2 Safety FOAMS sra iris ies 17 E O E ERE ae nee ea a AA 18 4 5 Various suggestions sucinta iii 20 OPERATIONAL FEATURES 00 o 21 5 1 PP Pe 22 DESCRIPTION OF THE GONNEGTORS oo onde AA pk po b ks do 23 6 1 Connectors of the logic Traction configuration oocnnnncccccnnnaccccncnnonacnncnnnarncncnnnnnos 23 6 2 Connectors of the logic Pump configuration srerrrnnnrennrnnnnvrnnnornrrrnnnrnnrrrnnnnrnnnnen 24 6 3 Description of power connections nannwwawanananaawannnnaaaanannanannanasaarnanaasasananns 25 DRAWING EO AA AA 26 7 1 Mechanical drawing ACE2 eorrnnnvnnnnnrnrrnnnannnrrrnnnnnnnrrnnennnnnnnnnnnnnvnnnnnrnnrnnnnnrnnrnnnsennnnnn 26 7 2 Mechanical drawing ACE2 POWer rernrrnnnnonnrrnnnnnnnnrnnnnnnnvennnnrnnrnnnnensnrrnnsrrrrrnesernnnnee 27 7 3 Connection drawing Traction configuration coonnncccnnnnnnccccnnnnccccnccnnnacncnnnanannncnnnnr 28 7 4 Connection drawing Pump ConfiguratiON ooocccnnncccccnnnncccccnnnnccccncnnnnannnc nana ncnnnnnnnnos 29 7 5 Connection drawing Combi ConfiguratiON ococcnnnnccccnnnncccccnnnnncnccnnnnnannnccnnnannnn cnn noo 30 PROGRAMMING 8 ADJUSTMENTS USING DIGITAL CONSOLE rrnnnnnvvnnnnnnnnvnnnnennnnnnnr 31 8 1 Adjustments via Console rarrnnrnnnnnnrnrrnnnonnnnrnnnnannnnnnnennnnvnnnnnnnnnnnnnnrnrrnnnenrnnrnnesennnn 31 8 2 Description of Console amp Connectio
36. correct start Incorrect starting sequences Traction Pump motor Start up stand Traction Pump MDI code is stopped by request allarm 79 Vacc out of The accelerator input is out Traction Pump motor Start up stand Traction Pump range of the range Vacc min is stopped by running request MDI code Vacc_max which has been allarm 85 acquired with PROGRAMM VACC function Temperature The controller has reached Traction controller Continuous MDI code the thermal cutback reduces the max allarm 62 temperature of 85 C when current linearly from the current is Imax Imax 85 C down to OA 105 C Motor Motor temperature sensor is The maximum current Continuous temperature opened if digital or has is reduced to half and MDI code overtaken the threshold of speed is reduced allarm 65 150 C if analogue Brake run out The Brake potentiometer No effect the warning Continuous Traction Pump input is at the maximum is only displayed request value without the HB request through the console Handbrake A traction request is done Traction motor is Stand by Traction Pump with the Handbrake input stopped running request active Current Gain The Maximum current gain Controller works but Start up stand MDI code parameters are the default with low maximum by allarm 92 values which means the current maximum current adjustment procedure has not been carried out yet Sens mot The output of the motor The ma
37. d then opens back again check Motor connections If motor phases windings cables have leakages towards truck frame Ifno problem are found on the motors the problem is inside the controller replace it AF2ZPOCL ACE2 User Manual 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 less than 66 of the rail capacitor voltage this alarm occurs Cause 2 Motor running test When the motor is running power bridge is ON the motor voltage feedback is tested if it is lower than commanded value a window of values are considered fault status is entered Troubleshooting Ifthe problem occurs at start up the LC does not close at all check Motor internal connections ohmic continuity Motor power cables connections Motor leakage to truck frame If the motor connections are OK the problem is inside the controller replace it Ifthe alarm occurs during motor running check Motor connections If motor phases windings cables have leakages towards truck frame That the LC power contact closer properly with a good contact If no problem are found on the motors the problem is inside the controller replace it 18 STBY HIGH Cause The current transducer or the current feedback circuit is damaged in the contro
38. e necessary to update the charge with the new value measured decrease lt is used to calibrate the discharge algorithm with the battery of the application See chapter 9 5 for more information LOAD HM FROM MDI When set On the HourMeter of the Controller is transferred and recorded on the HourMeter of the Standard MDI connected on the Serial Link 10 CHECK UP DONE Turn it On when the required Maintenance service has been executed to cancel the CHECK UP NEEDED warning 11 CHECK UP TYPE It specifies the handling of the CHECK UP NEEDED warning NONE No CHECK UP NEENED warning OPTION 1 CHECK UP NEENED warning shown on the hand set and MDI after 300 hours OPTION 2 Equal to OPTION 1 but Speed reduction after 340 hours OPTIONA 3 Equal to OPTION 2 but the truck definitively stops after 380 hours 12 MAIN CONT VOLT It specifies the percentage of battery voltage supplied to MC coil to close the contactor 13 AUX OUT VOLT It specifies the percentage of battery voltage supplied to AUX coil to close the AUXILIARY electro valve 14 MAIN CONT V RID It specifies the percentage of MAIN CONT VOLT parameter supplied to MC coil to keep the contactor closed Example 1 MAIN CONT VOLTAGE 100 MAIN CONT V RID 70 The contactor will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70 of battery voltage Example 2 MAIN CONT VOLTAGE 70 MAIN CONT V RID 100
39. e brake is not installed The truck is not electrically hold on a slope but comes down very It drives the coil of a a when the time set by electromaanetic brake auxiliary time parameter is d t si The le steering function alla e bi applied and request is sent to the pump ie a phase bridge S apenn Do inverter by the can bus link not use this combination if the negative brake is not installed It drives the coil of a hydraulic The truck is electrically hold on a HYDRO steering contactor when the slope when the time set by CONT ON direction input or brake pedal auxiliary time parameter is input are active ora movement of elapsed the truck comes down the truck is detected The very slowly till the flat is reached hydraulic steering function request is also sent to the pump inverter by the can bus link It drives the coil of a hydraulic HYDRO OFF steering contactor when the The truck is not electrically hold on CONT direction input or brake pedal a slope but comes down very input are active or a movement of slowly till the flat is reached the truck is detected The hydraulic steering function request is also sent to the pump inverter by the can bus link It drives the coil of a hydraulic The truck is electrically hold on a EXCL ON steering contactor when the slope when the time set by HYDRO exclusive hydro input is active auxiliary time parameter is The hydraulic steering function elapsed the truck comes down requ
40. e coil and then the voltage will be kept at the same value Example 3 MAIN CONT VOLTAGE 70 MAIN CONT V RID 70 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 17 AUX OUTPUT V RID It specifies the percentage of AUX OUT VOLT parameter supplied to EB coil to keep the electro mechanic brake applied Example 1 MAIN CONT VOLTAGE 100 MAIN CONT V RID 70 The Ebrake will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70 of battery voltage Example 2 MAIN CONT VOLTAGE 70 MAIN CONT V RID 100 The Ebrake will be closed with 70 of battery voltage applied to the coil and then the voltage will be kept at the same value Example 3 MAIN CONT VOLTAGE 70 AF2ZPOCL ACE2 User Manual Page 37 85 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 STOP A18 OUTPUT ON OUTPUT BEHAVIOUR ON A SLOPE RAMP The truck is electrically hold on a It drives the coil of a slope when the time set by BRAKE ON electromagnetic brake auxiliary time parameter is The hydraulic steering function elapsed the brake is applied and request is sent to the pump the 3 phase bridge is released Do inverter by the can bus link not use this combination if the negativ
41. e different type of alarms with the following information 1 The alarm code 2 The times that each alarm occurs consecutively 3 The Hour Meter value when the first event of every alarm occurred 4 And the inverter temperature when the first event of every alarm occurred This function permits a deeper diagnosis of problems as the recent history can be revised NOTE if the same alarm is continuously happening the controller does not use new memory of the logbook but only updates the last memory cell increasing the related counter point 2 of previous list Nevertheless the hourmeter indicated in this memory refers to the first time the alarm occurred In this way comparing this hourmeter with the controller hourmeter it is possible to determine When this alarm occurred the first time How many hours are elapsed from the first occurrence to now How many times it has occurred in said period AF2ZPOCL ACE2 User Manual Flow Chart showing how to use the ALARMS function via the Digital Console AE2T2B ZPO 12 24V 400A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General menu e z MAIN MENU 3 The Display will show PER 4 Press ROLL UP or ROLL DOWN button until mon PARAMETER CHANGE appears on the display ME e MAIN MENU ALARMS 5 The Display will show 6 Press ENTER to go into the ALARMS function oo Du oo CODE 00005 02 20 C 7 The Display will show the most recent Ala
42. e or can be dangerous or harmful for the operator items which are important to guarantee system performance and safety 4 1 Material overview Before to start it is necessary to have the required material for a correct installation Otherwise a wrong choice of cables or other parts could lead to failures misbehaviour bad performances 4 1 1 Connection cables For the auxiliary circuits use cables of 0 5 mm section For power connections to the motor and to the battery use cables having section of at least 50 mm The screwing torque for the controller power connection must be comprised in the range 13 Nm 15Nm For the optimum inverter performance the cables to the battery should be run side by side and be as short as possible 4 1 2 Contactors The main contactor must be installed Depending on the setting two parameters in the controller MAIN CONT VOLT V and MAIN CONT V RID see chapter 8 4 1 8 4 2 the output which drives the main contactor coil is modulated with a PWM at high frequency 1 kHz After an initial delay of about 1 sec in which the coil is driven with a percentage of Vbatt set by MAIN CONT VOLT parameter the PWM reduces the voltage down to a percentage which is set by the MAIN CONT V RID parameter This feature is useful to decrease the power dissipation of the contactor coil 4 1 3 Fuses Usea10A Fuse for protection of the auxiliary circuits For protection of the power unit refer to chapt
43. ealised the motor speed and torque control 3 Sensorless version using only the phase voltage feedback is implemented the motor speed and torque control with the Zapi patented sensor less control software Here the Sensored Version is descripted it adopts an Encoder integrated in the Ball Bearing Sensor Bearing The Encoder fills up the truck performance respect to the Sensorless and Sense Coils versions with lower minimum speed the stop on the ramp service and a smoother inversion on the other hand the reliability gets penalized by the fragile mechanics and inaccessible position of the Sensor Bearing AF2ZPOCL ACE2 User Manual Page 5 85 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 ko 15 16 AA AA AA AA 24 36 48 V Maximum current ACE2 24V 400 doocconocccccnonccccccnoncnccncnanancninonns 400 A RMS for 3 Maximum current ACE2 36 48V 350 rnnnnnnvvnnnrvnnvrnnrerrrrnnnerennr 350 A RMS for 3 1 hour current rating ACE2 24V 400 rnnnnnnnnrnrrnnnnnrnnrrnnnnrnnrrnnnennnnene 200 A RMS 1 hour current rating ACE2 36 48V 350 ulunan nanana nanan nnaa nananana anan 170 A RMS es ic AE mo 8 kHz External temperature range ccooccccnnonoccccnononcccnnnnannncnnnnnnnnnnnnannananenns 30 C 40 C Maximum inverter t
44. emperature at full power rrnanonnvrnrnnnnnrrnnrrrnrrrnnnrnnnnn 85 2 2 Technical specifications ACE2 Power Page 6 85 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 YO Ue A E 24 36 48 80V Maximum current ACE2 24V 500 mnnnrnnnnnnnvnnnrrnnvnnnnnrnrrnnnerennn 500 A RMS for 3 Maximum current ACE2 36 48V 450 rnrnnnnvvnnnrnnnvrnnrrrrrrrnnsrennn 450 A RMS for 3 Maximum current ACE2 80V 300 annrrnnnnnnnvvnnrrrnnrrnnrrrrrrrnnerennr 300 A RMS for 3 1 hour current rating ACE2 24V 500 rrnnrnnnnonnrrrnnnrerrrrnnnernrrrennrnnnnnn 250 A RMS 1 hour current rating ACE2 36 48V 450 rnnrrnrrnnnnnrnrrrnnnennvrennnnnnnnen 225 A RMS 1 hour current rating ACE2 80V 300 rarnnnnnrnrrnnnnnrnnrrnennrnnrrnnnnnnnnene 125 A RMS paraaan PAN NA 8 kHz External temperature range rrnnnnnnnrrrnnnnnnnvnnnnnnnnvnnnnnnnnnnnnnrnrnnnnenrnnn 30 C 40 C Maximum inverter temperature at full power rrranonnrrnrnnnnnrrnnrrrnrrrnnnrnnnnn 85 C AF2ZPOCL ACE2 User Manual 23 Block diagram CHIAVE m POTENZIOMETRO Pp MICROSWITCHES H 7 CONSOLE DI CON TROLLDO DI MOTORE ENCODER AF2ZPOCL ACE2 User Manual Page 7 85 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP
45. ents of main applied MDI code allarm 71 RAM registers and Traction Pump find a dirty value stopped Page 72 85 AF2ZPOCL ACE2 User Manual 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 The problem is in the microcontroller flash memory which could be damaged or in the program stored inside which could be corrupted Try to program the logic again if the alarms is still signalled the problem is in the microcontroller Replace the ACE logic board 2 ANALOG Cause This alarm occurs when the A D conversion of the analog inputs gives frozen value on all of the converted signals for more than 400msec The goal of this diagnosis is to detect a failure of the A D converter or a problem in the code flow that omits the refreshing of the analog signal conversion Troubleshooting If the problem occurs permanently it is necessary to substitute ACE logic board 3 WRONG SET BATTERY Cause At start up the controller checks the battery voltage and verify it is within a window around the nominal value Troubleshooting Check that the controller SET BATTERY parameter value matches the battery nominal voltage Check that TESTER MENU BATTERY VOLTAGE parameter shows same value as the battery
46. er The chain starts from the BATT post of the controller that works with the highest current and the others are connected in a decreasing order of power Otherwise if two controllers are similar in power for example a traction anda pump motor controller and a third module works with less current the best way to deal this configuration is to create a common ground point star configuration Correct Layout Module 1 Center of the Ground connection Module 3 Note Module 1 power Module 2 power gt Module 3 power In this case the power cables starting from the two similar controllers must be as short as possible Of course also the diameter of the cable concurs in the voltage drops described before higher diameter means lower impedance so in this last example the cable between the minus of the Battery and the common ground point pointed by the arrow in the image must be dimensioned taking into AF2ZPOCL ACE2 User Manual account thermal and voltage drop problems EY 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 simplified design readily available multi sourced components and tools lower costs less and smaller cables improved reliability fewer connections analysis of problems improved easy connection with a pc to read the data flowing th
47. er 9 Recommended spare parts for inverter The Fuse value shown is the maximum allowable For special applications or requirements these values can be reduced For Safety reasons we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow AF2ZPOCL ACE2 User Manual Page 11 85 a2 Installation of the hardware A 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 compromise safety After operation even with the Key Switch open the internal capacitors may remain charged for some time For safe operation we recommend that the battery is disconnected and a short circuit is made between Battery Positive and Battery Negative power terminals of the inverter using a Resistor between 10 ohm and 100 ohm 4 2 1 Positioning and cooling of the controller Install the inverter with the base plate on a flat metallic surface that is clean and unpainted Apply a light layer of thermo conductive grease between the two surfaces to permit better heat dissipation Ensure that the wiring of the cable terminals and connectors is carried out correctly Fit transient suppression devices to the horn solenoid valves and contactors not connected to the controller The heat generated by the power block must be dissipated Fo
48. er voltage threshold is 65V under voltage threshold is 11V Troubleshooting Troubleshooting of fault displayed at start up or in standby in these cases it is very likely the fault is due to an under voltage so it is suggested to check Key input signal down going pulses below under voltage threshold due to external loads like DC DC converters starting up relays or contactor switching solenoids energizing de energizing Check the connection of power cables to the battery terminal positive AF2ZPOCL ACE2 User Manual Page 75 85 Page 76 85 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 probably in the controller hardware so it is necessary to replace the logic board Troubleshooting of fault displayed during motor driving in this case it can be an under voltage or an over voltage condition If the alarm happens during traction acceleration or driving hydraulic functions it is very likely it is an under voltage condition check battery charge condition power cable connection Ifthe alarm happens during release braking it is very likely it is due to over voltage condition check line contactor contact battery power cable connection 14 LOGIC FAILURE 3 Cause Hardware problem in the logic card c
49. erature C of cooling air In case of thermal dissipation realised with the controller base plate installed on truck frame it is important the thickness of frame and the planarity and roughness of its surface If the alarm is signalled when the controller is cold the possible reasons are a thermal sensor failure or a failure in the logic card In this case it is necessary to replace the controller AF2ZPOCL ACE2 User Manual Page 81 85 Page 82 85 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 TESTER menu check the sensor ohmic value and the sensor wiring If the sensor is OK improve the cooling of the motor If the warning is present when the motor is cool then the problem is inside the controller BRAKE RUN OUT Cause The CPOTBRAKE input red by the microcontroller is at the maximum value without the hand brake request Troubleshooting Check the mechanical calibration and the functionality of the brake potentiometer If the alarm is not disappeared the failure is in the ACE logic board replace it HAND BRAKE Cause The hand brake input is active when a traction request is done Troubleshooting The possible reasons for this alarm are use the readings in the TESTER to facilitate the troubleshoo
50. error code to be displayed is in the harness or in the load coil So the very first check to carry out concerns connections between controller outputs and loads In case no failures problems have been found externally the problem is in the controller which has to be replaced 26 CONTACTOR OPEN Cause The main contactor coil has been driven by the controller but the contactor does not close Page 78 85 AF2ZPOCL ACE2 User Manual Troubleshooting It could be a problem of the contacts in the MC that are not working does not pull in try replacing the MC Ifthe contactors of MC are working correctly than the problem is in the controller replace it 27 LOGIC FAILURE 2 Cause Fault is in the hardware section of the logic board which manages the phase s voltage feedback Troubleshooting This type of fault is not related to external components so when it happens it is necessary to replace the ACE2 logic board 28 CONTACTOR DRIVER Cause The MC coil driver is not able to drive the load The device itself or its driving circuit is damaged Troubleshooting This type of fault is not related to external components replace the ACE2 logic board 29 AUX DRIVER OPEN Cause The EB AUX coil driver is not able to drive the load The device itself or its driving circuit is damaged Troubleshooting This type of fault is not related to external components replace the ACE2 logic board 30 ENCODER ERRO
51. est is also sent to the pump very slowly till the flat is reached inverter by the can bus link It drives the coil of a hydraulic EXCL OFF steering contactor when the The truck is not electrically hold on HYDRO exclusive hydro input is active a slope but comes down very The hydraulic steering function slowly till the flat is reached request is also sent to the pump inverter by the can bus link Page 38 85 AF2ZPOCL ACE2 User Manual SUBMENU SPECIAL ADJUST 1 2 ADJUSTMENT 01 Reserved ADJUSTMENT 02 Reserved SET CURRENT It adjusts the regolation of maximum current It shouldn t be changed HIGH ADRESS Reserved DEBUG MODE Reserved INVERTER TYPE It decides what kind of inverter is used 0 and 1 traction 2 and 3 pump The change of this parameter changes the other parameters at the next keyofi SAFETY IN 0 input allways closed bridged 1 safety in drived safety came from a different controller need a can handshake 2 general purpose input not jet defined Need hardware change SAFETY OUT 0 none fa comunque la diag all init per verificare il funzionamento 1 driver is for drive a safety in 2 general purpose standard function reverse direction indicator MAIN CONTACTOR OFF No main contactor directly connect to Battery ON Main contactor in stand alone config OPTION 1 Traction pump 1 only MC OPTION 2 Traction pump2 MC 10 AUX OUT FUNCTION 8 4 2 Pu
52. ete system is carried out by the traction inverter the information about the pump inverter consumption is sent on the can bus line from the pump inverter to the traction inverter So the correct programming for the Battery check option is traction inverter ON pump inverter OFF STOP ON RAMP ON the stop on ramp feature truck pump electrically hold on with load is managed for a time established by auxiliary time parameter OFF the stop on ramp feature is not performed AUX OUTPUT 1 Not used SET MOT TEMPERATURE ANALOG an analogue motor thermal sensor is connected between A22 and A23 inputs the curve can be customized on a customer request DIGITAL a digital ON OFF motor thermal sensor is connected between A22 and A23 inputs NONE no motor thermal sensor switch is connected AF2ZPOCL ACE2 User Manual 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 also curve below 4 THROTTLE X POINT This parameter together with the THROTTLE Y POINT changes the characteristic of the lift potentiometer input curve when the potentiometer is depressed to X point per cent the corresponding pump speed is Y point per cent of the Maximum pump speed The relationship between the lift potentiometer pos
53. eter in the middle at rest still in combination with a couple of Travel demand switches Na The Procedure for automatic potentiometer signal acquisition is carried out using the Console This enables adjustment of the minimum and maximum useful signal level PROGRAM VACC function in either direction This function is unique when it is necessary to compensate for asymmetry with the mechanical AF2ZPOCL ACE2 User Manual elements associated with the potentiometer especially relating to the minimum level The sequence of procedure is described in the programming console manual gt gt gt gt gt gt gt gt ss NNN p EN The two graphs show the output voltage from a non calibrated potentiometer with respect to the mechanical zero of the control lever MI and MA indicate the point where the direction switches close 0 represents the mechanical zero of the rotation The Left Hand graph shows the relationship of the motor voltage without signal acquisition being made The Right Hand Graph shows the same relationship after signal acquisition of the potentiometer 3 3 Other analog control unit 1 Input A10 is an analog input whose typical application is for proportional braking It should be in a 3 wire configuration Potentiometer value should be in the 0 5 10 kQ range Generally the load should be in the 1 5 mA to 30 mA range The CPOTB A10 signal range is from 0 to 10 V 2 Connections A22 PTHE
54. eys until the second Main indicates a FREE storage facility SELECT MOD O1 FREE 9 Press ENTER to commence SAVE routine ae 10 You can see the items that are being stored READING whilst the SAVE routine is happening AGCEL DELAY ECC 11 When finished the Console shows 12 Press OUT to return to the Opening Zapi Display El El El Omgd AF2ZPOCL ACE2 User Manual Page 63 85 8 11 Description of Console RESTORE function Page 64 85 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 The data that is available via the RESTORE PARAM function is as follows All Parameter Values PARAMETER CHANGE Options SET OPTIONS The level of the Battery ADJUST BATTERY ATTENTION When the RESTORE operation is made all data in the inverter memory will be written over and replace with data being restored Flow Chart showing how to use the RESTORE function of the Digital Console AE2T2B ZPO 12 24V 400A 00000 1 Opening Zapi Display 0HE O ood 2 Press ENTER to go into the General menu MAIN MENU 3 The Display will show PARAMETER GHANGE 4 Press ROLL UP or ROLL DOWN button until mon RESTORE PARAM appears on the Display mon MAIN MENU RESTORE PARAM 5 The Display will show 6 Press ENTER
55. he discharge algorithm with the battery of the application See chapter 9 5 for more information 11 LOAD HM FROM MDI When set On the HourMeter of the Controller is transferred and recorded on the HourMeter of the Standard MDI connected on the Serial Link Page 36 85 AF2ZPOCL ACE2 User Manual 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 i spo the handling of the CHECK UP NEEDED warning NONE No CHECK UP NEENED warning OPTION 1 CHECK UP NEENED warning shown on the hand set and MDI after 300 hours OPTION 2 Equal to OPTION 1 but Speed reduction after 340 hours OPTION 3 Equal to OPTION 2 but the truck definitively stops after 380 hours 14 MAIN CONT VOLT It specifies the percentage of battery voltage supplied to MC coil to close the contactor 15 AUX OUT VOLT It specifies the percentage of battery voltage supplied to EB coil to apply the electro mechanic brake 16 MAIN CONT V RID It specifies the percentage of MAIN CONT VOLT parameter supplied to MC coil to keep the contactor closed Example 1 MAIN CONT VOLTAGE 100 MAIN CONT V RID 70 The contactor will be closed with full battery voltage applied to the coil and then the voltage will be reduced to 70 of battery voltage Example 2 MAIN CONT VOLTAGE 70 MAIN CONT V RID 100 The contactor will be closed with 70 of battery voltage applied to th
56. he responsibility for the truck safety features and related approval ACE 2 inverter electronic implements an hardware safety circuit which is able to open the Line Contactor LC and the Electric Brake EB and therefore to cut the power line stopping the machine via HARDWARE that is bypassing the software control of the LC and EB This safety circuit is driven by SAFETY input If safety input is connected to BATT the SAFETY circuit is inactive if the input is open the SAFETY circuit becomes active and within a timeout it is able to open the drivers of LC coil and EB coil The safety circuit is also periodically checked by the ACE 2 microcontroller if the microcontroller detects a AF2ZPOCL ACE2 User Manual Page 17 85 failure in the SAFETY circuit the microcontroller itself will bring the machine in a safe status nuggeslad connection of SAFETY circuit STANDALONE CONFIGURATION it is suggested to connect safety input to the SEAT microswitch or to the DEADMAN microswitch it depends on the application in this way the machine will be brought to a safe status as soon as the operator leaves the machine COMBI CONFIGURATION in this case the pump controller acts as supervisor checking the traction controller functionality by the CANBUS So it is suggested to connect the SAFETY input of traction controller to a dedicated output of pump controller SAFETY OUT so that the pump controller can drive the traction s
57. i TEMP V BATT 5 ALARMS V MOT VMN MOT 6 ACCELERATOR 7 MOTOR DATA t 1 3 5 t o ROLL ENTER SET BUT TUNS ROLL OUT SET ite A EN API Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA minimum Release Number 3 02 AF2ZPOCL ACE2 User Manual Page 31 85 8 3 Description of Standard Console Menu 8 3 1 Traction configuration 03255 HANDLE SEAT RUNNING KEY ON PRESENT ABSENT ON OFF ON OFF HYDRO CONT BRAKE EXCL ANALOG DIGITAL NONE HYDRO Page 32 85 v V 24 36 48V N lt 0 9 ON OFF ON OFF NONE OPTION 1 2 3 HEADING JAIN MENU a ACCELERATIO Sec SET MODEL E CHANGE a 2 CONNECTED TO ACCELERATION 1 Sec ACCELERATION 2 Sec ACCELERATION 3 Sec ACC PROF FREQ I Hz ACC PROF FREQ 2 Hz ACC PROF FREQ 3 Hz i E HOUR COUNTER DECEL BRAKING SO CUTBACK MODE PEDAL BRAKING Sec de op SPEED LIMIT BRK Sec SA Me MAX SPEED FORW Hz ea MAX SPEED BACK Hz os CUTBACK SPEED 1 i FREQUENCY CREEP Hz MAXIMUM CURRENT BRK SMOOTH STOP BRK SMOOTH Hz A E Can ones Ue nial ADJUSTMENTS SET POT BRK MIN SET POT BRK MAX SET BATTERY TYPE TESTER BATTERY VOLTAGE V ADJUST BATTERY OTOR VOLTAGE THROTTLE 0 ZONE VOLTAGE BOOSTER T
58. ion refer to Console manual Switch the key off and on to check the result If the alarm occurs permanently it is necessary to replace the controller If the alarm disappears the previously stored parameters will have been replaced by the default parameters 13 FORW BACK Cause This alarm occurs when both the travel demands Fwd and Bwd are active at the same time Troubleshooting Check the wiring of the Fwd and Rev travel demand inputs use the readings in the TESTER to facilitate the troubleshooting Check the microswitches for failures A failure in the logic is possible too So when you have verified the travel demand switches are fine working and the wiring is right it is necessary to replace the ACE 2 logic board AF2ZPOCL ACE2 User Manual Page 83 85 9 RECOMMENDED SPARE PARTS FOR INVERTER Part number Description ACE Version C16588 Protected 350 A strip UL Fuse 24V 400 amp 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 UL Fuse 80V 300 C16520 10 A 20 mm Control Circuit Fuse All C29523 SW 180 80 V All Single Pole Contactor C29522 SW 180 48 V All Single Pole Contactor C29508 SW 180 24 V All Single Pole Contactor C12531 Connector Ampseal 23 pins Female All C12372 Connector Molex 8 pins Female All Page 84 85 AF2ZPOCL ACE2 User Manual 10 PERIODIC MAINTEN
59. ion listing shows the relative measurements 8 9 1 Traction 1 BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch 2 MOTOR VOLTAGE This is the RMS voltage supplied to the motor by the inverter it is expressed as a percentage of the full voltage which depends of the battery voltage 3 VOLTAGE BOOSTER This is the booster of the voltage supplied to the motor in load condition it is expressed in a percentage of the full voltage 4 FREQUENCY This is the frequency of the voltage and current supplied to the motor 5 ENCODER This is the speed of the motor expressed in the same unit of the frequency this information comes from the speed sensor 6 SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor expressed in the same unit of the frequency 7 CURRENT RMS Root Mean Square value of the motor current 8 MOTOR POWER It is the power provided to the motor 9 BATTERY CHARGE The percentage Charge level of the battery 10 TEMPERATURE The temperature measured on the aluminium heat sink holding the MOSFET devices 11 MOTOR TEMPERAT This is the temperature of the motor if the option is programmed None see chapter 8 4 1 it shows 0 12 ACCELERATOR The voltage of the accelerator potentiometer s wiper CPOT The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 13 HANDLE SEAT switch
60. ircuit for high current overload protection Troubleshooting This type of fault is not related to external components so when it is present it is necessary to replace the ACE logic board 15 POWER MOS SHORTED Cause Before switching the MC on the software checks the power bridge it turns on alternatingly the Low side and High side Power Mosfets and expects the phases voltage to decrease down to BATT increase up to Batt If the phases voltage do not follow the commands this alarm occurs Troubleshooting This type of fault is not related to external components replace the controller 16 VMN HIGH Cause 1 Before switching the LC on the software checks the power bridge it turns on alternatingly the Low side Power Mosfets and expects the phases voltage to decrease down to BATT If the phases voltage is higher than 10 of nominal battery voltage this alarm occurs Cause 2 This alarm may occur also when the start up diagnosis is overcome and so the LC is closed In this condition the phases voltages are expected to be lower than 1 2 Vbatt If it is higher than that value fault status is entered Troubleshooting Ifthe problem occurs at start up the LC does not close at all check Motor internal connections ohmic continuity Motor power cables connections If the motor connection are OK the problem is inside the controller replace it If the problem occurs after closing the LC the LC closed an
61. it communication among the various electronic modules of a vehicle connected as illustrated in this image CAN Controller Transceiver E The best cable for can connections is the twisted pair if it is necessary to increase the immunity of the system to disturbances a good choice would be to use a cable with a shield connected to the frame of the truck Sometimes it is sufficient a simple double wire cable or a duplex cable not shielded Ina system like an industrial truck where power cables carry hundreds of Ampere there are voltage drops due to the impedance of the cables and that could cause errors on the data transmitted through the can wires In the following figures there is an overview of wrong and right layouts of the cables routing A Wrong Layout Module Module 1 2 Module 3 The red lines are can wires The black boxes are different modules for example traction controller pump controller and display connected by canbus AF2ZPOCL ACE2 User Manual Page 13 85 Page 14 85 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 preferable connection is the daisy chain Correct Layout Module 2 Module 3 Note Module 1 power gt Module 2 power gt Module 3 pow
62. ition and the pump speed is linear between the THROTTLE 0 ZONE and the X point and also between the X point and the maximum potentiometer position but with two different slopes 5 THROTTLE Y POINT This parameter together with the THROTTLE X POINT changes the characteristic of the lift potentiometer input curve see also paragraph 13 5 when the potentiometer is de pressed to X point per cent the corresponding pump speed is Y point per cent of the Maximum pump speed The relationship between the potentiometer position and the pump speed is linear between the THROTTLE 0 ZONE and the X point and also between the X point and the maximum accelerator position but with two different slope VACC MIN and VACC MAX are values programmable by the Program Vacc function S f A 6 BATT MIN ADJ It adjusts the lower level of the battery discharge table It is used to calibrate the discharge algorithm with the battery of the application See chapter 9 5 for more information AF2ZPOCL ACE2 User Manual Page 41 85 Page 42 85 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 ADJUSTMENT 03 This parameter adjusts the updating of battery charge after Key On Decreasing this parameter the minimum difference between the battery voltage measured after Key On and the last stored valu
63. larm A18 is active when input REVERSE is active or when motor is drived in reverse direction 8 SET MOT TEMPERATURE DIGITAL adigital ON OFF motor thermal sensor is connected between A22 and A23 inputs ANALOG an analogue motor thermal sensor is connected between A22 and A23 the curve can be customized on a customer request NONE no motor thermal sensor switch is connected 9 AUX INPUT 1 This parameter decide if input A10 is used for brake or for quick inversion BRAKE A10 is used like brake pedal BELLY A10 is used like quick inversion input There s inversion until A10 is closed TIMED A10 is used for quick inversion request and inversion is timed 10 2 5 POT ON when the potentiometer is under the half range level is backward When is over is forward Forward and backward microswitches are not present Enable is A4 11 BACKING ON Inching function is available Enable input on A19 Forward direction request input on A4 reverse direction request input on A5 12 EPS ON EPS is present SUBMENU ADJUSTMENTS 1 SET POT BRK MIN It records the minimum value of braking pedal potentiometer when the braking switch is closed the procedure is similar to the Program Vacc function see chapter 9 4 This procedure must be carried out only if the Pedal braking option is programmed as Analog 2 SET POT BRK MAX It records the maximum value of braking pedal potentiometer when the braking pedal is fully pressed
64. larm stopped status Coil shorted MC Shortcircuit on MC MC is opened Start up Traction Pump MDI code allarm 76 Coil EB is applied immediately after Request Traction Pump MC closing stopped stand by running Coil shorted EF Shortcircuit on MC is opened Start up Traction Pump MDI code allarm 68 EB AUX coil EB is applied immediately after Request Traction Pump MC closing stand stopped by running Contactor open The MC coil has MC is opened Start up Traction Pump MDI code allarm 77 been driven but MC EB is applied immediately after Request does not close Traction Pump MC closing stopped Stand by running Logic failure 2 Motor phases MC is opened Start up Traction Pump MDI code allarm 55 voltage feedback EB is applied immediately after Request circuits are Traction Pump MC closing damaged stopped Contactor driver Driver of MC coil is MC is opened the Stand by running Traction Pump MDI code allarm 75 damaged not able command is Request to close released EB is applied Traction Pump stopped Aux Driver Open Driver of EB AUX MC is opened EB Stand by running Traction Pump coil is damaged is applied Request not able to apply Traction Pump the brake stopped Encoder Error Problem on the MC is opened EB is Running Traction Pump MDI code allarm 82 encoder reading applied Request Traction Pump stopped Wrong Ram The program checks MC is opened EB is Continuous Key re cycle Memory the cont
65. ller Troubleshooting This type of fault is not related to external components so when it is present it is necessary to replace the controller 19 WRONG 0 VOLTAGE Cause At start up the high resolution VMN feedback is not comprised in a permitted window of values centred around 2 5V The circuit is damaged in the controller Troubleshooting It is suggested to check Motor internal connections ohmic continuity Motor power cables connections Motor leakage to truck frame Ifthe motor connections are OK the problem is inside the controller replace the logic board 20 CONTACTOR CLOSED Cause Before driving the MC coil the controller checks if the contactor is stuck The controller drives the bridge for some tens milliseconds trying to discharge the capacitors bank If the capacitor voltage does decrease by 20 of the key voltage the alarm is generated Troubleshooting It is suggested to verify the power contacts of LC to replace the LC is necessary AF2ZPOCL ACE2 User Manual Page 77 85 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 inside the controller no external component are involved replace the logic board 22 HARDWARE FAULT 21 Cause Before driving the MC coil the controller checks if the E
66. logic Traction configuration A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 KEY PPOT CPOT FORW REV SEAT ENCA PENC BATT CPOTBR SAFETY IN CAN T SR HB ENCB ENC GND NLC PLC PB NEB SAFETY OUT AF2ZPOCL ACE2 User Manual Connected to the power supply through a microswitch CH with a 10 A fuse in series Potentiometer positive 12 V 5 V output keep load 5 1 kohm 0 5 kohm Accelerator potentiometer wiper Forward direction request input It must be connected to the forward direction microswitch active high Backward direction request input It must be connected to the backward direction microswitch active high It can also be used as NPOT potentiometer negative reference with the PEDAL WIRE KO diagnosis implemented SEAT input it must be connected to the SEAT microswitch it is active when connected to BATT Incremental encoder phase A input Incremental encoder positive supply 12 V 5 V Negative power supply It is used as NPOT without PEDAL WIRE KO diagnosis for acceleration potentiometer and brake potentiometer Brake potentiometer wiper If not connected to Batt the MC and EB coil power output will be disabled In the COMBI configuration it is connected to SAFETY OUT CNA 19 of pump controller This input can also be used as a general purpose digital input If it is connected with A21 CAN H it introduces
67. logic board 11 WATCHDOG 2 Cause At start up the watch dog signal is already active before the software has generated it At stby or running condition the watch dog signal is not active in alarm status Troubleshooting The WD hardware circuit or microcontroller output port are damaged In both cases no external component are involved Replace the logic board 12 KEYOFF SHORTED Cause This fault is displayed when the controller detects a low logic level of Key Off signal during Start Up diagnosis Troubleshooting It is very likely the fault is due to an under voltage so it is suggested to check Key input signal down going pulses below under voltage threshold due to external loads like DC DC converters starting up relays or contactor switching solenoids energizing de energizing Check the connection of power cables to the battery terminal positive 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 probably in the controller hardware so it is necessary to replace the logic board 13 LOGIC FAILURE 1 Cause This fault is displayed when the controller detects an over voltage or under voltage condition Over voltage threshold is 45V under voltage threshold is 9V in the 24V controller In 48V controller ov
68. lure is in the ACE logic board replace it 2 INCORRECT START Cause This is a warning for an incorrect starting sequence Troubleshooting The possible reasons for this alarm are use the readings in the TESTER to facilitate the troubleshooting Atravel demand active at key on Presence man sensor active at key on Check the wirings Check the micro switches It could be also an error sequence made by the operator A failure in the logic is possible too so when all of the above conditions were checked and nothing was found replace the ACE logic board 3 VACC OUT OF RANGE Cause The CPOT input red by the microcontroller is not comprised in the range Vacc_min Vacc_max programmed through the PROGRAMM VACC function Troubleshooting Acquire the maximum and minimum potentiometer value through the PROGRAM VACC function If the alarm is still present check the mechanical calibration and the functionality of the potentiometer If the alarm is not disappeared the failure is in the ACE logic board replace it 4 TEMPERATURE Cause This alarm occurs when the temperature of the base plate is higher than 85 Then the maximum current decreases proportionally with the temperature increases from 85 up to 105 At 105 the Current is limited to O Amps Troubleshooting It is necessary to improve the controller cooling For realise an adequately cooling in case of finned heat sink are important factor the flux m3 h and temp
69. mp ON OFF If OFF A18 is not drived and there is no diagnosis on it Using the config menu of the programming console the user can configure the following functions SUBMENU SET OPTIONS 1 DISPLAY TYPE This parameter decides wich display is connected to the inverter 0 No Display 1 MDI PRC connected 2 ECO DISPLAY connected AF2ZPOCL ACE2 User Manual Page 39 85 Page 40 85 3 SMART DISPLAY connected 4 MDI CAN connected 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 is managed as tiller input no delay when released SEAT CNA 6 is managed as seat input with a delay when released debouncing function HOUR COUNTER RUNNING the counter registers travel time only KEY ON the counter registers when the key switch is closed CUTBACK MODE OPTION 1 A13 is third speed request PRESENT A13 is speed reduction request OPTION 2 A13 has no function BATTERY CHECK ON the battery discharge level check is carried out when the battery level reaches 10 an alarm is signalled and the maximum current is reduced to the half of the programmed value OFF the battery discharge level check is carried out but no alarm is signalled Very important In the combi system pump traction the battery discharge calculation for the compl
70. n aranrrrnrnannnvvnnnnnnnvrnnnnrnnvnnnnrrrrrrnnererrrrnnnerennnn 31 8 3 Description of Standard Console MENU arrrrrnrrnnnnvvnnnrnnnnvnnnrnnnrrnnnrernrrrnnerrrrrnnnennnnn 32 8 3 1 Traction configuration cda desatada 32 8 3 2 Pump configuration escitas dadas 33 8 4 Function configuration oooonccnnnnnnccnccnnncccnnnnonencnnnnnnnnncnnnnnnnnnnnnnnnnncncn ran cnn nc rannnnnnnnnnes 34 AF2ZPOCL ACE2 User Manual Page 3 85 8 4 1 Traclom sn 34 842 PUN o o 39 8 5 Parameter regulation EEE daic ise 49 850 TN 49 8 5 2 PP 52 8 6 Programming console functions Uma NANG ca 56 8 7 Sequence for Ac Inverter Traction setting 002200muucananuanunaaasunanananassasana 57 8 8 Sequence for Ac Inverter Pump SettINQ coooccccnnnnnccccnnnoncccccnnnccncnnonanancnnnnnnnnnnnnnnns 58 8 9 Tester description of the function ananawwaawananaaawannnaaaanannnaaaanananaaanaasasanaana 59 8 94 TR NN 59 8 92 PP 60 8 10 Description of the Console SAVE fUNCtON oooccccnnnncccc nnnccccccnnnnccccccnnnnannncnnnanncnncnnno 63 8 11 Description of Console RESTORE function rrrrrrrrnnvrvnvnrnnnvennrrrnrrnnnrrrrrrrnnnrnnnnn 64 8 12 Description of Console PROGRAM VACO function rvrrrnnnvrnnrrvnvrrnnnrrrrrrnnnrnnnnn 65 8 13 Description of the battery charge detection setting rrrrirrrrrreeverrrrenaasnoronaann 67 8 14 Description of ALARMS MENU eerannnnnornan
71. n an hydraulic steering function request is switched off The following table shows the minimum maximum programmable value for each parameter In the table is also present the parameters resolution PARAMETER UNIT MIN VALUE MAX VALUE RESOLUTION ACCELERATION 0 Sec 0 3 10 0 1 ACCELERATION 1 Sec 0 3 10 0 1 ACCELERATION 2 Sec 0 3 10 0 1 ACCELERATION 3 5 Sec 0 3 10 0 1 ACC PROF FREQ 1 Hz 0 200 1 ACC PROF FREQ 2 Hz 0 200 1 ACC PROF FREQ 3 Hz 0 200 1 RELEASE BRAKING Sec 0 3 10 0 1 MAX SPEED LIFT Hz 5 200 1 1 SPEED COARSE Hz 5 200 1 2 SPEED COARSE Hz 5 200 1 3 SPEED COARSE Hz 5 200 1 HYD SPEED FINE Hz 5 200 1 CUTBACK SPEED 1 Max Sp 10 100 1 FREQUENCY CREEP Hz 0 3 2 0 1 MAXIMUM CURRENT IMAX 0 100 1 AUXILIARY TIME Sec 0 10 1 Page 54 85 AF2ZPOCL ACE2 User Manual Flow Chart showing how to make Programme changes using Digital Console fitted with Eprom CK ULTRA AE2T2B ZPO 12 1 Opening Zapi Display 24V 400A 00000 E O 2 Press ENTER to go into the General Menu 5 3 The Display will show MAIN MENU PARAMETER GHANGE 4 Press ENTER to go into the Parameter Change facility oo 5 The Display will show the first parameter e a 2 6 Press either ROLL UP and ROLL DOWN to mon display the next parameter mon 7 The names of the Parameters appear on the INV ACCEL O Displa
72. n the operator is present There are two levels HANDLE CNA 6 is managed as tiller input no delay when released SEAT CNA 6 is managed as seat input with a delay when released debouncing function HOUR COUNTER RUNNING the counter registers travel time only KEY ON the counter registers when the key switch is closed CUTBACK MODE OPTION 1 PRESENT or OPTION 2 option 2 5 POT is ON OPTION 1 A13 is a handbrake PRESENT A13 is a speed reduction request OPTION 2 no function for A13 If option 2 5 POT is OFF OPTION 1 A13 is a handbrake PRESENT A13 is a speed reduction request OPTION 2 A13 is enable input BATTERY CHECK ON the battery discharge level check is carried out when the battery level reaches 10 an alarm is signalled and the maximum current is reduced to the half of the programmed value OFF the battery discharge level check is carried out but no alarm is signalled STOP ON RAMP ON the stop on ramp feature truck electrically hold on a ramp is managed for a time established by auxiliary time parameter After this time the behaviour depends on the aux output 1 option programming see also the following table AF2ZPOCL ACE2 User Manual 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 A
73. ncy in Hz the acceleration is defined by the AF2ZPOCL ACE2 User Manual 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 ACCELERATION 3 parameter 8 RELEASE BRAKING Seconds It controls the deceleration ramp when the pump request is released The parameter sets the time needed to decelerate the traction motor from 100Hz to OHZ 9 MAX SPEED LIFT It determines the pump maximum speed when LIFT ENABLE switch is closed 10 1ST SPEED COARSE It determines the pump maximum speed when SPEED1 switch is closed 11 2ND SPEED COARSE It determines the pump maximum speed when SPEED2 switch is closed 12 3RD SPEED COARSE It determines the pump maximum speed when SPEEDS switch is closed 13 HYD SPEED FINE It determines the pump maximum speed when an hydraulic steering function request is received via CAN BUS 14 CUTBACK SPEED 1 Speed reduction when the cutback input is active 15 FREQUENCY CREEP AF2ZPOCL ACE2 User Manual Page 53 85 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 delay whe
74. ne is electrically hold on a slope for a programmable time see also chapter 8 4 Stable speed in every position of the accelerator Regenerative release braking based upon deceleration ramps Regenerative braking when the accelerator pedal is partially released deceleration Direction inversion with regenerative braking based upon deceleration ramp Regenerative braking and direction inversion without contactors only the main contactor is present The release braking ramp can be modulated by an analog input so that a proportional brake feature is obtained Optimum sensitivity at low speeds Voltage boost at the start and with overload to obtain more torque with current control The inverter can drive an electromechanical brake Hydraulic steering function traction inverter the traction inverter sends a hydraulic steering function request to the pump inverter on the can bus line see also OPTIONS chapter 8 4 moreover if the pump inverter is not present for ex tractor application the traction inverter can manage an hydraulic steering function by driving a hydro contactor which drive an hydraulic steering motor output A18 see also OPTIONS chapter pump inverter the pump inverter manage an hydraulic steering function That is it drives the pump motor at the programmed speed for the programmed time High efficiency of motor and battery due to high frequency commutations
75. nnnnnnnnnnnnnennernanvnnnnnrnnvennnnrnnnnnnennnnreneeennnnn 68 8 15 Faults diagnostic system vesen 69 8 16 Microcontroller alarms Overview ul aa aaa a ama 70 8 17 Analysis and troubleshooting of alarms displayed on console s 73 8 18 Microcontroller warning overview ron nnnnnnnnr cnn nenes 80 8 19 Analysis and troubleshooting of warnings displayed on COnSOlE eeeeeeeeross 81 9 RECOMMENDED SPARE PARTS FOR INVERTER nnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 84 10 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED ccceeee 85 APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN PROJECT MANAGER FG TECHNICAL ELECTRONIC pp MANAGER VISA SALES MANAGER VISA MC Publication N AF2ZPOCL Edition July 2009 Page 4 85 AF2ZPOCL ACE2 User Manual 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 order pickers reach truck CB 2 0 tons tractors boom lift and scissors lift The ACE 2 can be supplied in three versions 1 Sensored version using an Encoder Sensor Bearing in the Motor axle is realised an extremely precise and reliable motor speed and torque control 2 SenseCoils version using special auxiliary windings inside the motor instead of an encoder is r
76. on is changed but not completely released The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz 13 SPEED LIMIT BRK Seconds It controls the deceleration ramp when a speed reduction has been activated The parameter sets the time needed to decelerate the traction motor from 100Hz to OHZ 14 TIL REL BRAKING Seconas It controls the deceleration ramp when the tiller is released The parameter sets the time needed to decelerate the traction motor from 100Hz to OHz 15 MAX SPEED FORW It determines the maximum speed in forward direction 16 MAX SPEED BACK It determines the maximum speed in backward direction Page 50 85 AF2ZPOCL ACE2 User Manual 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 reverse switch is closed but the accelerator is on a minimum position 21 MAXIMUM CURRENT This parameter changes the maximum current of the inverter 22 BRK SMOOTH It gives a parabolic form to the deceleration ramp 23 STOP BRK SMOOTH Hz It sets the level of frequency where the smooth effect of the deceleration parabolic form ends 24 CURVE CUTBACK Determines the speed reduction in curve only if the EPS is present 25 STEER DEAD ANGLE Under this angle the curve cutback is not a
77. p configuration Page 24 85 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 KEY PPOT CPOT LIFT ENABLE SPEED1 SEAT ENCA PENC BATT SPEED2 SAFETY IN CAN T SPEED3 Connected to the power supply through a microswitch CH with a 10 A fuse in series Potentiometer positive 12 V 5 V output keep load 5 1 kohm 0 5 kohm Lifting potentiometer wiper Input for potentiometer lifting enable input it is active HIGH Input for first speed request it is active HIGH It can also be used as NPOT potentiometer negative reference with the PEDAL WIRE KO diagnosis implemented SEAT input it must be connected to the SEAT microswitch it is active when connected to BATT Incremental encoder phase A input Incremental encoder positive supply 12 V 5 V Negative power supply It is used as NPOT without PEDAL WIRE KO diagnosis for lifting potentiometer Input for second speed request it is active HIGH If not connected to Batt the AUX1 and AUX2 coil power output will be disabled It can also be used as a general purpose digital input If it is connected with A21 CAN H it introduces the 120 Ohm termination resistance between CAN L and CAN H Input for third speed request it is active when AF2ZPOCL ACE2 User Manual A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 B1 B2 B3 B4 B5 B6 B7 B8 ENCB ENC GND NLC PLC PAUX NAUX SAFETY OUT CAN L C
78. pplied only if the EPS is present 26 AUXILIARY TIME Time units value seconds For the encoder version it determines the time duration the truck is hold on the ramp if the STOP ON RAMP option is ON The following table shows the minimum maximum programmable value for each parameter In the table is also present the parameters resolution PARAMETER UNIT MIN VALUE MAX VALUE RESOLUTION ACCELERATION O Sec 0 3 10 0 1 INV ACCEL 0 Sec 0 3 10 0 1 ACCELERATION 1 5 Sec 0 3 10 0 1 ACCELERATION 2 Sec 0 3 10 0 1 ACCELERATION 3 Sec 0 3 10 0 1 ACC PROF FREQ 1 Hz 0 200 1 ACC PROF FREQ 2 Hz 0 200 1 ACC PROF FREQ 3 Hz 0 200 1 RELEASE BRAKING Sec 0 3 10 0 1 INVERS BRAKING Sec 0 3 10 0 1 DECELERATION BRAKING Sec 0 3 10 0 1 PEDAL BRAKING Sec 0 3 10 0 1 SPEED LIMIT BRAKING Sec 0 3 10 0 1 AF2ZPOCL ACE2 User Manual Page 51 85 MAX SPEED FW Hz 5 200 1 MAX SPEED BW Hz 5 200 1 CUTBACK SPEED 1 YoMax 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 8 5 2 Pump Page 52 85 The acceleration time shown is the time from 0 Hz to 100 Hz This is the ideal ramp calculated by the software the real ramp could change as a function of motor contro parameter setting and obviously as
79. r 9 4 5 Set the MAXIMUM CURRENT Current using the table on Chapter 8 5 1 6 Set the Acceleration Delay requirements for the machine Test the parameters in both directions 7 Set the FREQUENCY CREEP level starting from level 0 3 Hz The machine should just move when the accelerator microswitch is closed Increase the Level accordingly 8 Set the Speed Reductions as required Make adjustments to CUTBACK SPEED Check the performance with the accelerator pedal totally depressed If the machine is a forklift check the performance with and without load 9 RELEASE BRAKING Operate the machine at full speed Release the accelerator pedal Adjust the level to your requirements If the machine is a forklift check the performance with and without load 10 INVERSION BRAKING Operate the machine at 25 full speed Whilst travelling INVERT the Direction Switch Set a soft Level of Inversion Braking When satisfactory operate the machine at Full Speed and repeat If the machine is a Forklift repeat the tests and make adjustments with and without load The unloaded full speed condition should be the most representative condition 11 DECELERATION BRAKING Operate the machine at full speed Release the accelerator pedal until 50 of its range is reached Adjust the level to your requirements If the machine is a forklift check the performance with and without load 12 PEDAL BRAKING If used Operate the machine at full Speed Release the
80. r this to be possible the compartment must be ventilated and the heat sink materials ample The heat sink material and system should be sized on the performance requirement of the machine Abnormal ambient air temperatures should be considered In situations where either ventilation is poor or heat exchange is difficult forced air ventilation should be used The thermal energy dissipated by the power block module varies and is dependent on the current drawn and the duty cycle 4 2 2 Wirings power cables Page 12 85 The power cables length must be as short as possible to minimize power losses They must be tightened on controller power posts with a Torque of 13 15 Nm The ACE2 module should only be connected to a traction battery Do not use converters outputs or power supplies For special applications please contact the nearest Zapi Service Centre Do not connect the controller to a battery with a nominal voltage different than the value indicated on the controller label A higher battery voltage may cause power section failure A lower voltage may prevent the logic operating AF2ZPOCL ACE2 User Manual 4 2 3 Wirings CAN connections and possible interferences EY 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 company Bosch to be used in the car industry to perm
81. rameter changes the other parameters at the next keyoff SAFETY IN 0 input allways closed bridged 1 safety in drived safety came from a different controller need a can handshake 2 general purpose input not jet defined Need hardware change SAFETY OUT 0 none fa comunque la diag all init per verificare il funzionamento 1 driver is for drive a safety in 2 general purpose standard function reverse direction indicator MAIN CONTACTOR OFFNo main contactor directly connect to Battery ON Main contactor in stand alone config OPTION 1 Traction pump 1 only MC OPTION 2 Traction pump2 MC 10 AUX OUT FUNCTION Page 44 85 ON OFF If OFF A18 is not drived and without diagnosis AF2ZPOCL ACE2 User Manual Flow chart showing how to make changes to OPTION Menu EO E ood 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter SET Menu 3 The Display will show SET MODEL 4 Press ROLL UP or ROLL DOWN button until SET MODEL Menu appears 5 SET OPTIONS appears on the display 6 Press ENTER to go into the SET MODEL Menu 7 The display will shows the first OPTION 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 Desired OPTION appears 10 Press SET UP or SET DOWN button in order to modify the changes 11 New OPTION appears 12 Press OUT to exit the Menu 13 Confirmation request appears 14 Press ENTER to accept the changes or press O
82. rm 8 Each press of the ROLL UP button brings up following Alarms Pressing ROLL DOWN returns to the most recent 9 If an Alarm has not occurred the Display will CODE show ALARM NULL 00007 03 18 C 10 When you have finished looking at the Alarms press OUT to exit the ALARMS menu 11 The Display will ask CLEAR LOGBOOK api ee et YES ENTER NO OUT 12 Press ENTER for yes or OUT for NO 13 Press OUT to return to the Opening Zapi Display 8 15 Faults diagnostic system The fault diagnostic system of ACE 2 controller is divided into 2 main groups of faults ALARMS these are the faults which open the power section which means the power bridge is opened and when possible the LC is opened and EB is applied These are faults related to failures in the motor controller that the power system is not anymore able to drive the truck safety related failures AF2ZPOCL ACE2 User Manual Page 69 85 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 devices These warnings are related to wrong operator sequences conditions which require performance reduction like high temperatures fe 6Microcontroller alarms overview Error Description
83. rough the cable 4 2 4 Wirings I O connections After crimping the cable verify that all strands are entrapped in the wire barrel Verify that all the crimped contacts are completely inserted on the connector cavities A A cable connected to the wrong pin can lead to short circuits and failure so before turning on the truck for the first time verify with a multimeter the continuity between the starting point and the end of a signal wire For information about the mating connector pin assignment see the paragraph description of the connectors 4 2 5 Connection of the encoder 1 ACE2 card is fit for different types of encoder To control AC motor with Zapi inverter it is necessary to install an incremental encoder with 2 phases shifted of 90 The encoder power supply can be 5 or 12 V It can have different electronic output A8 5V 12V positive of encoder power supply A15 GND negative of encoder power supply A7 ENCA phase A of encoder A14 ENC B phase B of encoder 2 Connection of encoder with 5 V power supply AF2ZPOCL ACE2 User Manual Page 15 85 Connection of encoder with 12 V power supply S A 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 way by Zapi 4 2 6 Main contactor and key connection The connection of the m
84. ry of closed switch OFF GND non active entry of open switch 16 2ND SPEED SWITCH Status of the second speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 17 3RD SPEED SWITCH Status of the third speed switch of the pump ON GND active entry of closed switch OFF VB non active entry of open switch 18 HYDRO SPEED REQ Status of the hydro speed request of the pump ON an hydro speed request is received via Can Bus OFF no hydro speed request active 19 CUTBACK SWITCH The level of the Speed Reduction Microswitch ON GND active entry of speed reduction microswitch OFF VB non active entry of microswitch 20 2ND HOURMETERS This parameter displays the working hour of pump controller AF2ZPOCL ACE2 User Manual Page 61 85 Flow Chart showing how to use the TESTER function of the Digital Console a Tm AE2T2B ZPO 12 1 Opening Zapi Display 2 Press ENTER to go into the General menu MAIN MENU 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until mon TESTER MENU appear on the display goa 5 The Display shows TESTER 6 Press ENTER to go into the TESTER function 7 The first variable to be tested is shown on the BATTERY VOLTAGE Display 8 Press either ROLL UP or ROLL DOWN buttons until your desired variable for measurement appears on the Display 9 When you have finished Pre
85. ss OUT 10 The Display shows 11 Press OUT again and return to Opening Zapi Display MAIN MENU TESTER Remember it is not possible to make any changes using TESTER All you can do is measure as if you were using a pre connected multimeter 21 Other functions Page 62 85 AF2ZPOCL ACE2 User Manual 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 the Console memory can then be reloaded into another inverter using the RESTORE function The data that is available via the SAVE function is as follows All Parameter Values PARAMETER CHANGE Options SET OPTIONS The Level of the Battery ADJUST BATTERY Flow Chart showing how to use the SAVE function of the Digital Console AE2T2B ZPO 12 24V 400A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General menu a A a MAIN MENU PARAMETER GHANGE 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until SAVE PARAM appears on the display BOO BOO 5 The Display will show 6 Press ENTER to go into the SAVE function 7 If this facility has been used before the type of inverter data stored appears on the top Main with a 2 digit reference SELECT MOD OO FREE 8 Keep pressing either ROLL UP or ROLL DOWN k
86. t is expressed in a percentage of the full voltage 4 FREQUENCY This is the frequency of the voltage and current supplied to the motor 5 ENCODER This is the speed of the motor expressed in the same unit of the frequency this information comes from the speed sensor 6 SLIP VALUE This is the difference of speed between the rotating field and the shaft of the motor expressed in the same unit of the frequency 7 CURRENT RMS Root Mean Square value of the motor current 8 MOTOR POWER It is the power provided to the motor 9 BATTERY CHARGE The percentage Charge level of the battery 10 TEMPERATURE The temperature measured on the aluminium heat sink holding the MOSFET devices 11 MOTOR TEMPERATURE This is the temperature of the motor if the option is programmed None see chapter 8 4 2 it shows 0 12 HANDLE SEAT switch The level of the Handle Seat digital entry ON GND active entry of closed switch OFF VB non active entry of open switch 13 LIFTING CONTROL The voltage of the lift potentiometer s wiper CPOT The voltage level is shown on the Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 14 LIFT ENABLE Status of the lifting switch Page 60 85 AF2ZPOCL ACE2 User Manual 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 ent
87. t up stand by Key re cycle MDI code allarm 86 open it is not EB is applied running connected to Batt Traction Pump stopped Page 70 85 AF2ZPOCL ACE2 User Manual Safety out The Safety out MC is not closed Start up Traction Pump driver is damaged EB is applied request shorted or open Traction Pump stopped Watchdog 1 The watchdog MC is opened Start up stand by Key re cycle MDI code allarm 8 signal 1 is not in EB is applied running the correct status Traction Pump stopped Watchdog 2 The watchdog MC is opened Start up stand by Key re cycle MDI code allarm 8 signal 2 is not in EB is applied running the correct status Traction Pump stopped Keyoff shorted At Start up the Key MC is not closed Start up Key re cycle MDI code allarm 76 off EB is applied logic signal is low Traction Pump stopped Logic Failure 1 An undervoltage MC is not closed Start up stand by Traction Pump MDI code allarm 54 overvoltage EB is applied running request condition has been Traction Pump detected stopped Logic failure 3 High current HW MC is not closed Start up Traction Pump MDI code allarm 17 protection circuit is EB is applied request damaged Traction Pump stopped Power mos shorted Short circuit on the MC is not closed Start up Traction Pump MDI code allarm 89 power Mosfets EB is applied request Traction Pump stopped Vmn high Motor output MC is not
88. te RF energy but wires and cables have the key role to propagate the disturbs because they works as antennas so a good layout of the cables and their shielding can solve the majority of the emission problems 2 The study of the immunity can be divided in two main branches protection from electromagnetic fields and from electrostatic discharge The electromagnetic immunity concern the susceptibility of the controller with regard to electromagnetic fields and their influence on the correct work made by the electronic device There are well defined tests which the machine has to be exposed to These tests are carried out at determined levels of electromagnetic fields to Page 18 85 AF2ZPOCL ACE2 User Manual 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 is created on a material and it remains there it becomes an electrostatic charge ESD happens when there is a rapid transfer from a charged object to another This rapid transfer has in turn two important effects this rapid charge transfer can determine by induction disturbs on the signal wiring and thus create malfunctions this effect is particularly critical in modern machines with serial communications canbus which are spread everywhere on the truck and which c
89. ter CONFIG Menu 3 The Display will show SET MODEL 4 Press ROLL UP button until ADJUSTMENTS Menu appears 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will show SET BATTERY TYPE 8 Press SET UP to choose nominal value of the battery 9 New battery value appears 10 Press OUT 11 Confirmation request appears 12 Press ENTER to accept the changes or press OUT if you do not accept the changes 13 Press OUT Display now shows the Opening Zapi Menu AF2ZPOCL ACE2 User Manual AE2T2B ZPO 12 24V 400A 00000 CONFIG MENU SET MODEL Bod ood CONFIG MENU ADJUSTMENTS Deo BE 8 SET BATTERY TYPE BOV ODO ood SET BATTERY TYPE 48V 000 Deo ARE YOU SURE YES ENTER NO OUT Page 47 85 Page 48 85 Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG Menu 3 The Display will show SET MODEL 4 Press ROLL UP button until ADJUSTMENTS Menu appears 5 ADJUSTMENTS appears on the display 6 Press ENTER to go into the ADJUSTMENTS Menu 7 The display will show the first OPTION 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 ADJUST BATTERY appears 10 Press SET UP or SET DOWN button in order to increase or decrease respectively Set the value read by an e
90. ting The HB switch is damaged so it does not close the input CNA 13 to Batt Replace it The HB switch work correctly but in the tester menu the HB input is always ON In this case the failure is in the logic board replace it CURRENT GAIN Cause The Maximum current gain parameters are at the default values which means the maximum current adjustment procedure has not been carried out yet Troubleshooting Ask the assistance of a Zapi technician to do the correct adjustment procedure of the current gain parameters SENS MOT TEMP KO Cause The output of the motor thermal sensor is out of range Troubleshooting Check the sensor ohmic value and the sensor wiring If the sensor is OK then the problem is inside the ACE logic board replace it 10 THERMIC SENS KO Cause The output of the controller thermal sensor is out of range Troubleshooting This type of fault is not related to external components replace the controller AF2ZPOCL ACE2 User Manual 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 memory supporting the controller parameters This alarm does not inhibit the machine operations but the truck will work with the default values Troubleshooting Try to execute a CLEAR EEPROM operat
91. tion on the motor Page 25 85 7 DRAWING 7 Mechanical drawing ACE2 I 1 f LU CITI Cm 3 o e co 8 TT TO Yo Available with 150X200X40 heat sink trasversal or longitudinal fins M8 Nut Power Fuse La 200 6 0 5 188 0 2 ki I HOLH l E l e Bu 58 go 2 28 ge 3 3 2E 8 3 o co a T xs ae NG D Do z2 ng Lu 5 Li c LE 33 Se TE S AX 265 5 X M8 Male Screw KO Existing others versions with or without power fuse With heat sink 200x40x150mm longitudinal transversal Page 26 85 AF2ZPOCL ACE2 User Manual 72 Mechanical drawing ACE2 Power Ki o LU EJ pe en EFE E 09 5 pama os A yy N o gt Available with 200X200X40 heat sink trasversal or longitudinal fins M8 Nut paa Fuse La 200 620 5 188 0 2 10 5 _ I A I I Su NN o DN 23 A7 52 L8 Q e 8 Ss 8 2 8 a fa oF 2 q Er oN 2 XE oa o os Do pe a 2 ga x lt 8 c n o R N us fl OG z2 j N Se o Es as o 1 lt E 1
92. tion that could cause damage or compromise safety the matter should be bought to the attention of a Zapi Agent immediately The Agent will then take the decision regarding operational safety of the machine Remember that Battery Powered Machines feel no pain NEVER USE A VEHICLE WITH A FAULTY ELECTRONIC CONTROLLER A IMPORTANT NOTE ABOUT WASTE MANAGEMENT This controller has both mechanical parts and high density electronic parts printed circuit boards and integrated circuits If not properly handled during waste processing this material may become a relevant source of pollution The disposal and recycling of this controller has to follow the local laws for these types of waste materials Zapi commits itself to update its technology in order to reduce the presence of polluting substances in its product AF2ZPOCL ACE2 User Manual Page 85 85
93. to go into the RESTORE PARAM omo Function ood 7 The Display shows the type of Model stored with a Code Number 8 Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on m a the Display SELECT MOD O1 API V1 9 Press ENTER to commence the Restore omo operation Dano 10 The Display will ask ARE YOU SURE ARE YOU SURE YES ENTER NO OUT 11 Press ENTER for YES or OUT for No AF2ZPOCL ACE2 User Manual 12 You can see the items that are being stored in the inverter memory whilst the RESTORE routine is eee ee E LAW happening 13 When finished the Console displays GAB ha 14 Press OUT to return to the Opening Zapi Display 8 12 Description of Console PROGRAM VACC function This enables adjustment of the minimum and maximum useful signal level in either direction This function is unique when it is necessary to compensate for asymmetry with the mechanical elements associated with the potentiometer especially relating to the minimum level The two graphs show the output voltage from a non calibrated potentiometer with respect to the mechanical zero of the control lever MI and MA indicate the point where the direction switches close 0 represents the mechanical zero of the rotation The Left Hand graph shows the relationship of the motor voltage without signal acquisition being made The Right Hand Graph shows the same relationship after sign
94. ver of the main contactor coil is shorted Troubleshooting Check if there is a short or a low impedance pull down between NMC CNA 16 and BATT The driver circuit is damaged in the logic board which has to be replaced AUX DRIVER SHORTED Cause The driver of the electro mechanic brake auxiliary electro valve coil is shorted Troubleshooting Check if there is a short or a low impedance pull down between NEB NAUX CNA 18 and BATT The driver circuit is damaged in the logic board which has to be replaced SAFETY IN Cause The safety input is opened and accordingly the MC is opened an EB AUX OUT coil is driven Troubleshooting Check the CAN 11 input if it is connected to Batt and the alarm is generated then there is a fault in the SAFETY IN hardware circuit Replace the logic board SAFETY OUT Cause AF2ZPOCL ACE2 User Manual 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 up the watch dog signal is already active before the software has generated it At stby or running condition the watch dog signal is not active in alarm status Troubleshooting The WD hardware circuit or microcontroller output port are damaged In both cases no external component are involved Replace the
95. ximum current Continuous temp Ko thermal sensor is out of is reduced to half and MDI code range speed is reduced allarm 65 Thermic sens The output of the controller The maximum current Continuous Ko thermal sensor is out of is reduced to half and MDI code range speed is reduced allarm 61 Slip profile Error on the parameters of Traction Pump motor Start up stand Traction Pump MDI code the slip profile setting is stopped by running request allarm 99 EEPROM KO Error is detected in Eeprom Controller works continuous MDI code or in Eeprom management using default allarm 71 parameters Forward The travel demands are Traction is stopped Start up stand Traction Backward active in both directions at by running request MDI code the same time allarm 80 Page 80 85 AF2ZPOCL ACE2 User Manual 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 1 0V higher than PROGRAM VACC min acquisition when the accelerator is released Troubleshooting Acquire the maximum and minimum potentiometer value through the PROGRAM VACC function If the alarm is still present check the mechanical calibration and the functionality of the potentiometer If the alarm is not disappeared the fai
96. xternal meter 11 Battery value appears on the display 12 Press OUT to exit the Menu 13 Confirmation request appears 14 Press ENTER to accept the changes or press OUT if you do not accept the changes 15 ADJUSTMENTS Menu appears 16 Press OUT Display now show the Opening Zapi Menu AE2T2B ZPO 12 24V 400A 00000 CONFIG MENU SET MODEL CONFIG MENU ADJUSTMENTS SET BATTERY TYPE 48V Bod Bod ADJUSTMENT BATTERY 50 2V ADJUSTMENT BATTERY 50 6V ood 0HE O ARE YOU SURE YES ENTER NO OUT CONFIG MENU ADJUSTMENT AF2ZPOCL ACE2 User Manual 8 5 Parameter regulation In addition to the input configuration parameter modification is made directly by ZAPI on customer specifications or by the customer making the adjustments using the programming console 8 5 1 Traction The following parameters can be modified 1 ACCELERATION 0 It specifies the motor acceleration at O Hz At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases INV ACCEL 0 It specifies the motor acceleration at 0 Hz after an inversion of direction At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases ACCELERATION 1 It specifies the motor acceleration at ACC PROF FREQ 1 Hz At level 0 the acceleration is maximum Increasing the parameter s level the acceleration decreases ACCELERATION 2 It specifies
97. y 8 When the desired Parameter appears the Display will show the parameter value Press either SET UP Top Right or SET DOWN Bottom Right buttons to increase decrease the value 9 The Display will show the New Level 10 When you are satisfied with the results of the changes you have made Press OUT 11 The Display asks ARE YOU SURE ARE YOU SURE YES ENTER NO OUT 12 Press ENTER to accept the changes or press OUT if you do not wish to accept the changes and wish to make further modifications to the parameters MAIN MENU PARAMETER GHANGE 13 The Display will show AF2ZPOCL ACE2 User Manual Page 55 85 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 motor voltage motor voltage voltage booster voltage booster frequency Hz frequency Hz encoder Hz encoder Hz slip value Hz slip value Hz current rms A current rms A motor power W motor power W battery charge battery charge temperature C temperature C motor temperat C motor temperature C accelerator V handle seat switch ON OFF handle seat switch ON OFF lifting control V forward switch ON OFF lifting enable ON OFF

ACE2 INVERTER - ETP Kraftelektronik AB

Contents

Download Pdf Manuals

Related Search

Related Contents