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ACE5 INVERTER - Zapi Inc USA

1. I I ED LI fT ll a l ka A e m a dima _ S V l bil 3 x L O g E i l Leal an LI Y id Wo N Bl 1 1 VAN V f l IM Pl Ra Hy AAA AR AAA A po IN MENI II BERERE NI MANN AAN t 1 UU do UUVUVUVUVUUUUU b ax oor I l co to had Mm s Z a a o Se a B gt Rn A y cu co L c m o O S Z o OD S o 5 V ws N x ez gu 2 vo D 20 s oD ED AE S Z x z OG LO Li S ZO L vz BO a gt On Sa A so ag SI V i 4 X 2 co a anaes A os KE T L og 9s gt Le n2 4 Os 7E 1 Sea kek o Fi L 285 0 2 7 5 0 5 ni Me 300 m AFAZPOCB ACE5 INVERTER User Manual Page 27 72 72 Connection drawing Traction configuration l avaja ONIA yaad ONIddOLs LI A NI CANBUS 8 MOTOR TEMP SENSOR Je YVAN IN le Ci LI CI x Nen A ae m m t3 Su z Q E g x jas ea ol GJI rar ede a m E NM NM I al FE Li x LT El lt I lt T DE URNI E FA a wn LI RS Son e LE ASYNCHRONOUS TRACTION MING
2. PROGRAM N ASH F Page 28 72 AFAZPOCB ACE5 INVERTER User Manual 7 3 Connection drawing Pump configuration CONT COI SENSOR DR TEMP SE CANBUS a MOT R ISSSENNN fi a lt Od a LI MC ent e ss Se 3 a gt T TI lt z F F li LI li I T LJ LJ El EP ELE Li a T 1 lt O ao oo z z z lt a O Y BIE E AJ a T T a i gt ao Z a Ol GLO u Z n y a Noo mo m U du a a T lt T lt lt lt lt YNCHRONOUS PUMP AS A22 A13 AP l T KEY MC AFAZPOCB ACE5 INVERTER User Manual AMMINI H PROGR FLA Page 29 72 7 4 Connection drawing Combi configuration RACTION ASYNCHRONOUS EDA VING P A EDAL OPPING PEDA ST 9 MOTOR TEMP SENSOR CONSOLE e NIN Lt B6 Mo FLASH PROGRAMMING b B7 S NCHRONOUS li LOGIC B SRD m Al FLASH PROGRAMMING Page 30 72 AFAZPOCB ACE5 INVERTER User Manual 8 PROGRAMMING amp ADJUSTMENTS USING DIGITAL CONSOLE 8 1 Adjustments via Console Adjustment of Parameters and changes to
3. Output for driving the negative of main contactor coil single pump configuration or the negative of an auxiliary load It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is AFAZPOCB ACE5 INVERTER User Manual A27 A28 A29 A30 A31 A32 A33 A34 A35 B1 B2 B3 B4 B5 B6 B7 B8 AFAZPOCB ACE5 INVERTER User Manual PAUX NHYDRO PHYDRO CM MODE PPOT AUX KEY BATT BATT PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH FLASH 1 5A at 36 48V 0 5A at 80V and above Positive of the main contactor coil or of the auxiliary load It is equal to the key voltage Output for driving an hydraulic steering contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A at 80V and above Positive of the hydraulic steering contactor coil lt is equal to the key voltage Common of LIFT ENABLE 1ST 2ND 3RD 4TH HYDRO SR microswitches This input allows the customer to select the software for traction or lifting application Configuration Open not connected it is a Traction inverter Closed connected with A35 it is a pump inverter Auxiliary potentiometer positive It is the same voltage as A3 Keep load gt 1 kQ Connected to the power supply through a microswitch with a fuse in series It is a ground reference It is a ground reference Positive serial reception Neg
4. This could happen because e This pin is not connected to ground level single controller configuration Check the wires e The slave module has deactivated the output which holds the SAFETY input at low level master slave configuration Check the slave controller and the connection between master and slave e The SAFETY input circuit has an internal failure Replace the controller 27 SAFETY KO This alarm is present on some software version when a slave controller the pump in combi configuration uses one of its outputs to drive the SAFETY pin at low level At start up the master controller tests if the SAFETY input is not active while the slave controller has not yet activated its driver in this way the master can detect the presence of a short circuit between SAFETY pin and ground This alarm arises if a short is detected the MC does not close and any function is prevented Possible causes e The SAFETY pin has an external short check the wires e The output driver of the slave module is shorted check the slave controller and replace it if necessary e The internal SAFETY circuit has a failure replace the master controller 28 BATTERY LOW If the BATTERY CHECK parameter is set ON a battery discharge algorithm is executed When the estimated charge level is 10 this alarm is signalled and the current is reduced to the half of the programmed level 29 WRONG SET BATT When the key is turned ON the controller check the b
5. B of encoder Negative of accelerator unit This pin is tested for wire disconnection diagnosis Analog input for accelerator potentiometer wiper CAN termination connect to CAN H A18 to insert 1200 CAN termination resistance High level CAN BUS voltage I O Low level CAN BUS voltage I O It is a ground reference Analog input for brake potentiometer wiper Phase A inverted of encoder encoder with differential output AFAZPOCB ACE5 INVERTER User Manual A23 A24 A25 A26 A27 A28 A29 A30 A31 A32 A33 A34 A35 B1 B2 B3 B4 B5 B6 B7 B8 AFAZPOCB ACE5 INVERTER User Manual ENC B NTHERM PTHERM NMC PMC NBRAKE PBRAKE CM MODE PPOTB KEY BATT BATT PCLRXD NCLRXD PCLTXD NCLTXD GND 12 FLASH FLASH Phase B inverted of encoder encoder with differential output It is a ground reference Input for motor temperature sensor Output for driving the negative of main contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A at 80V and above Positive of main contactor coil It is equal to the key voltage Output for driving a brake or an hydraulic steering contactor coil It drives to Batt It can be on off controlled or PWM controlled Maximum dc current is 1 5A at 36 48V 0 5A at 80V and above Positive of the electromechanical brake coil It is equal to the key volta
6. Contents Us oi o a 5 2 OPEGIFIGATION sna etait ele kk ee ea ej rale n kk ak n a ak kk pk a ki ak 6 AT AGE5 technical SOCCIICALIONS isc en io l pw pp e ei ia e l ok ik pak ki ae 6 2 2 Block diagram y OOOO PA o A 2 6 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT 7 3 1 o a an a ana 7 32 MINS IU TNS A A cece tess tte n pi A A a V aa a ava 7 3 3 Accelerator WA kd kk nt ta n ak ki e a ala a m dan pe bab ekran ake 7 3 4 Other analog control devices 8 3 5 Speed TEGABGAOK k obze toi sta sot dak vos diab ceci ii 9 4 INSTALLATION HINTS sne mene ene pk n kt kk a a an kon Se a 10 nn P P P o n 10 4 1 1 Connection cables scsi ii isla 10 4 1 2 PUSS for VO Cr Suctaninano alii 10 4 1 3 Fuse for power section 10 4 2 Installation of the hardware 11 4 2 1 Positioning and cooling of the controller 11 4 2 2 Connection of power cables n 11 4 2 3 CAN connections and possible interferences 12 4 2 4 VOBGONNBOMONS aii eseja ni raid desas dd dlani a ka pe taste 14 4 2 5 Connection of the encoder nn 14 4 2 6 Main contactor and key connection 15 4 2 7 Insulation of truck frame nan 16 4 3 Hardware protection and safety features 16 4 3 1 Protection TBAUUTOS sita ide kr adi 16 E ae a a a ana 17 s a a EEA RE A
7. Left Hand Side of the Console Display and the value in percentage is shown on the Right Hand Side 9 LIFTING SWITCH Status of the lifting switch ON VB active entry of closed switch OFF GND non active entry of open switch AFAZPOCB ACE5 INVERTER User Manual 10 1ST SPEED SWITCH Status of the first speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 11 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 12 3RD SPEED SWITCH Status of the third speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 13 4TH SPEED SWITCH Status of the fourth speed switch of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 14 HYDRO SPEED REQ Status of the hydro speed request of the pump ON VB active entry of closed switch OFF GND non active entry of open switch 15 CUTBACK SWITCH The level of the Speed Reduction Microswitch ON GND active entry of speed reduction microswitch OFF VB non active entry of microswitch 16 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 17 BATTERY VOLTAGE Level of battery voltage measured at t
8. Manual nm SET MODEL SET OPTIONS ADJUSTMENTS CONNECTED TO 0 25 HA HOUR COUNTER BATTERY CHECK CUTBACK MODE HYDRO KEY ON STOP ON RAMP AUX OUTPUT 1 PEDAL BRAKING SET TEMPERATURE RUNNING KEY ON ON OFF PRESENT ABSENT ON OFF ON OFF HYDRO CONTACTOR EXCLUSIVE HYDRO BRAKE ANALOG DIGITAL ANALOG DIGITAL NONE AUX FUNCTION ON OFF ENABLE FUNCTION PRESENT ABSENT CHECK PUMP HYDRO ON OFF SET POT BRK MIN EN SET POT BRK MAX V SET BATTERY TYPE 24 36 48 72 80 96V ADJUST BATTERY aN THROTTLE O ZONE a THROTTLE X POINT s THROTTLE Y POINT A ADJUSTMENT 04 G ADJUSTMENT 0 ADJUSTMENT 0 9 ADJUSTMENT 0 9 LOAD HM FROM MDI ON OFF CHECK UP DONE ON OFF CHECK UP TYPE NONE OPTION 1 2 3 Page 33 72 8 4 2 Pump configuration HEADING MAIN MENU poo ACCELER DELAY 0 9 SET MODEL CONNECTED TO O vee DECELER DELAY 0 9 MAX SPEED UP iz MIN SP UP Hz CUTBACK SPEED x 1ST SPEED FINE iz 2ND SPEED FINE Hz 3RD SPEED FINE Hz SET OPTIONS HOUR COUNTER RUNNING KEY ON 4TH SPEED FINE Hz BATTERY CHECK ON OFF HYD SPEED FINE az SET TEMPERATURE DIGITAL ANALOG NONE MAXIMUM CURRENT 0 9 AUXILIARY TIME Sec TESTER MOTOR VOLTAGE ADJUSTMENTS o SET BATTERY TYPE 24 36 48 72 80 96V FRE
9. OFF GND non active entry of open switch 10 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 11 ENABLE SWITCH Status of the accelerator enable input ON VB active entry of closed switch OFF GND non active entry of open switch 12 SEAT SWITCH The level of the Seat switch digital entry ON VB active entry of closed switch OFF GND non active entry of open switch 13 BACKING F Status of the inching function forward direction input ON VB active entry of closed switch OFF GND non active entry of open switch 14 BACKING B Status of the inching function backward direction input ON VB active entry of closed switch OFF GND non active entry of open switch AFAZPOCB ACE5 INVERTER User Manual Page 51 72 8 8 2 Pump Page 52 72 15 CUTBACK SWITCH The level of the Speed Reduction Microswitch ON GND active entry of speed reduction microswitch OFF VB non active entry of microswitch 16 BRAKE SWITCH The level of the Pedal Brake Microswitch ON VB active entry of Brake pedal Microswitch OFF GND non active entry of microswitch 17 EXCLUSIVE HYDRO Status of the exclusive hydro input ON VB active entry of closed switch OFF GND non active entry of open switch 18 BRAKEPEDAL POT The percentage of the pressure on the brake pedal 1
10. be as short as possible to minimize power losses They must be tightened on controller power posts connection by using a torque of 24 30 Nm The ACES5 controller 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 from the value indicated on the controller label A higher battery voltage may cause a failure of the power section A lower voltage may prevent the AFAZPOCB ACE5 INVERTER User Manual Page 11 72 logic operating 4 2 3 CAN connections and possible interferences EP 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 lt was invented by the German company Bosch for the car industry lt permits communication among the various electronic modules of a vehicle The following image shows the typical connection MO CAN Controller Transceiver 12042 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 not shielded duplex cable In a system like an industrial truck where power cables c
11. deceleration ramp when the speed reduction input becomes active and the motor slow down The parameter value in seconds sets the time needed to slow down the motor from 100 to OHz 7 MAX SPEED FORW It determines the maximum speed in forward direction 8 MAX SPEED BACK It determines the maximum speed in backward direction 9 CUTBACK SPEED Speed reduction percentage of the max speed when the cutback switch is active 10 CURVE CUTBACK Determines the speed reduction percentage of the max speed during a steering movement and only if an electric steering control like a Zapi EPS is present in the truck 11 FREQUENCY CREEP Minimum speed in Hz when the forward or reverse switch is closed but the accelerator is at its minimum position 12 MAXIMUM CURRENT This parameter changes the maximum current of the inverter It is a percentage of the current defined by factory settings 13 BACKING SPEED It determines the speed while the inching function is active 14 BACKING TIME It determines the time duration of the inching function 15 AUXILIARY TIME During the time defined by this option the truck is hold on the ramp if the AFAZPOCB ACE5 INVERTER User Manual Page 47 72 stop on ramp option is ON The following table shows the different values at which the parameters can be set PROGRAMMED LEVEL KNENENENENEEKEKA SE KEN 0 25 EDI ES ES TAEAE 1 os uo ss EE 50 44 55 66 3 06 4 efe fete JER
12. external shorts or misconnections Check the EB coil wire e There is an internal failure Replace the controller 20 COIL SHORTED Inside the logic board there is a shunt in common with both the NMC and the NEB output drivers This shunt is used to detect overcurrent conditions in these outputs in case of an overcurrent event the NMC and ENB drivers are stopped and this alarm is raised Look for short circuit in parallel with the MC and EB coils or if these coils have the correct impedance If no short is present and the alarm persists the failure is internal to the controller which must be replaced The overcurrent detection circuit is checked at start up too If this test fails the alarm is raised In this case the failure is only internal to the logic board and the controller must be replaced 21 HIGH TEMPERATURE This is a warning and not an alarm It indicates that the controller temperature is greater than 75 C The maximum current is reduced proportionally to the temperature increase The controller current drops to zero at 100 C If the alarm is signalled when the controller is cold there is an internal failure and the controller must be replaced 22 MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens digital sensor or if the analog signal overtakes the cut off level defined by ADJUSTMENT 44 parameter The motor current is reduced to avoid any damage to the motor If it happens when t
13. finished looking at the Alarms press OUT to exit the ALARMS menu CLEAR LOGBOOK 11 The Display will ask CLEAR LOGBOOK YES ENTER NO OUT 12 Press ENTER for yes or OUT for NO 13 Press OUT to return to the Opening Zapi ooo Display omo 9 4 Description of Console PROGRAM VACC function Page 58 72 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 Flow Chart showing how to use the PROGRAM VACC function of the Digital Console AC5T2BF ZP1 00 SOV 10004 00000 1 Opening Zapi Display 2 Press ENTER to go into the General Menu OMO ood MAIN MENU PARAMETER GHANGE 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until NOG PROGRAM VACC appears on the display 18 MAIN MENU 5 The Display will show PROGRAM VACGC 6 Press ENTER to go into the PROGRAM VACC a routine ooo 7 The Display will show the minimum and i A A VAGG SETTING maximum values of potentiometer wiper output a m 4 8 4 8 Both directions can be shown 8 Press ENTER to clear these values Display will Omo show 0 0 ooo 9 Select Forward Direction close any interlock MIN VACC MAX switches that may be in the system 0 0 s 0 0 AFAZ
14. 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 AGST2BF ZP1 00 1 Opening Zapi Display BOV 1000A 00000 2 Press ENTER to go into the General menu a aa MAIN MENU PARAMETER GHANGE 3 The Display will show 4 Press ROLL UP or ROLL DOWN button until NOG RESTORE PARAM appears on the Display mon 5 The Display will show 6 Press ENTER to go into the RESTORE PARAM Do mo Function ooo 7 The Display shows the type of Model stored SELECT MOD OO with a Code Number AC5 ZAPI VI 8 Keep pressing either ROLL UP and ROLL DOWN buttons until the desired model appears on the Display SELECT MOD 01 AGC5 ZAPI V1 9 Press ENTER to commence the Restore omo operation odo 10 The Display will ask ARE YOU SURE ARE YOU SURE YES ENTER NO OUT 11 Press ENTER for YES or OUT for No AFAZPOCB ACE5 INVERTER User Manual 12 You can see the items that are being stored in the inverter memory whilst the RESTORE routine is happening STORING ACCELER DELAY MAIN MENU 13 When finished t
15. motor towards ground or towards battery B failure inside the inverter power stage replace it 13 VACC NOT OK The test is made in stand by when traction is not enabled yet This alarm says that the accelerator voltage is 1 V greater than the minimum value programmed by the PROGRAM VACC function Unless this alarm is removed any traction request will be ignored Possible causes A the potentiometer is not correctly calibrated Do the PROGRAM VACC procedure B the potentiometer is not correctly connected Check the cables C the potentiometer itself is defective Check the potentiometer 14 PEDAL WIRE KO The inverter continuously checks the NPOT pin to find out if the Page 62 72 AFAZPOCB ACE5 INVERTER User Manual potentiometer has been disconnected Inside the NPOT circuit there is a sense diode which is on only if the potentiometer is correctly connected between PPOT and NPOT If the controller detects the diode turn off the alarm is signalled because either PPOT or NPOT are not connected anymore Controller operation is prevented while this alarm is active Check the potentiometer cables if this alarm arises If the alarm persists there is an internal failure and the controller must be replaced 15 PEDAL FAILURE This alarm is activated if the accelerator analog signal voltage on CPOT pin is out of range too high or too small Controller operation is prevented while this alarm is active Possible causes the
16. of encoder power supply 5V or 12V output The output voltage must be configured by Zapi there is an internal jumper Negative of encoder power supply Accelerator potentiometer positive 5V or 12 V output The output voltage must be configured by Zapi there is an internal jumper Keep load gt 1 KQ SEAT input it must be connected to the SEAT microswitch lt is active high Forward direction request input it must be connected to the forward direction microswitch It is active high Backward direction request input it must be connected to the backward direction microswitch It is active high EX HYDRO ENABLE Exclusive hydro or accelerator enable function PB SR HB input it must be connected to the exclusive hydro microswitch or to the accelerator enable switch It is active high See also Chapter 8 6 Brake request input it must be connected to the brake pedal switch It is active high Speed reduction handbrake input It is active low switch opened See also Chapter 8 6 BACKING FORW Inching function forward direction input it must be BACKING BACK SAFETY ENC A ENC B NPOT CPOT CAN T CAN H CAN L NPOTB CPOTB ENC A connected to the inching forward switch It is active high Inching function backward direction input it must be connected to the inching backward switch It is active high If not connected to Batt the MC coil power output will be disabled Phase A of encoder Phase
17. on ramp option is ON set the desired value of auxiliary time parameter A Depending on the motor used it is necessary to set some parameters giving Zapi the motor curves it is possible to know the optimal setting in order to the motor runs efficiently AFAZPOCB ACE5 INVERTER User Manual Page 35 72 8 5 2 Pump Page 36 72 Select the Options required See Chapter 8 6 In particular Select and set the Battery voltage Select the type of motor temperature sensor Confirm correct installation of all wires Use the Console s TESTER Chapter 8 8 to assist Perform the lift signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on Chapter 9 4 Set the MAXIMUM CURRENT Current using the table in Chapter 8 7 Set the Acceleration and Deceleration Delay requirements for the pump Set the MIN SPEED UP level starting from O Hz The pump should just turn when the request microswitch is closed Increase the level accordingly Set the Speed Reductions as required Make adjustments to CUTBACK SPEED Check the performance with the full request Check the performance with and without load Set MAX SPEED UP max speed of pump motor Set HYD SPEED FINE to adjust the hydraulic steering speed pump motor speed when HYDRO function is requested 10 Set AUXILIARY TIME time delay before pump stops when an hydraulic steering function request is switched off De
18. pe A o aie terre eet ere tne re eer eens tee rere eee etree ee re err ree 37 8 0 2 PP eee eee ee ry ere 41 8 7 PARAMETER regulation usaste ideo neenaka 47 A en 47 A PUMP ene eee io it E an Pa eee eT errs 48 8 8 TESTER description of the functions 51 co Oe me o ere e cee ee re ere 51 O calf tea ei fia de vise eka fan de a tet ere eee ee er ee eer ee ee AE 52 OTHER FUNCTIONS siii 55 9 1 Description of Console SAVE function 55 9 2 Description of Console RESTORE function 56 9 3 Description of ALARMS MENU sici n an kankan nek ans 5 9 4 Description of Console PROGRAM VACO function 58 ACE5 DIAGNOSTIC ALARM DESCRIPTION nana nnnnnnnnnnnnnnnnenna 60 10 1 Analysis of alarms for Traction controller 60 10 2 Analysis of alarms for Pump controller 66 RECOMMENDED SPARE PARTS FOR INVERTER nana nana nana 71 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED 72 APPROVAL SIGNS COMPANY FUNCTION INITIALS SIGN PROJECT MANAGER TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Publication N AFAZPOCB Edition May 2011 Page 4 72 AFAZPOCB ACE5 INVERTER User Manual 1 INTRODUCTION Within the ZAPIMOS family the AC5 inverter is the model suitable for control of motors with power above 20 kW traction or above 50 kW pump It has been expressly designed for battery electric traction Typical applications
19. potentiometer has a failure for example the wiper is mechanically broken Check the potentiometer there is some problem in the connections Check the wires There is an internal failure in the controller Replace it 16 STBY HIGH Test carried out in stand by The controller checks if the current in stand by is zero If it is non zero this alarm is activated The controller opens the MC and it inhibits machine operations Possible causes A current sensor failure B logic board failure In both cases the controller must be replaced 17 DATA ACQUISITION This alarm is signalled in the current gain acquisition phase Wait the end of the acquisition activity EP The gain acquisition test can be carried out only by Zapi personnel or other trained technicians 18 MAIN CONTACTOR ALARMS The main contactor has many diagnoses related to it Here there is the complete list Notice that all of these alarm cause the opening of the MC and the stop of all functions of the controller DRIVER SHORTED When the key is switched ON the controller checks that the NMC pin is not at zero voltage If it is this alarm is signalled MC stay open and any function is prevented Possible causes are e Driver inside the NMC circuit is shorted The controller has to be replaced e An external short is present between NMC and ground Check the cables CONTACTOR DRIVER When all initial diagnoses are finished the traction logic tries to closes the MC by a
20. replace the controller 7 ENCODER ERROR Two consecutive readings of the encoder speed are too much different Page 66 72 AFAZPOCB ACE5 INVERTER User Manual because of the inertia of the system it is not possible the encoder changes its speed a lot in a short period The alarm is set to appear if the read speed changes of more than 40 Hz in few milliseconds This alarm stops the power bridge Possible causes an encoder failure has occurred e g one or two channels of the encoder are corrupted or disconnected Check both the electric and the mechanical encoder functionality the electromagnetic noise on the sensor bearing disturbs the encoder signal This event is quite common at low speed and very high motor currents when the bearing is not shielded 8 CAPACITOR CHARGE When the key is switched ON the inverter tries to charge the internal capacitor bank through a power resistance and it checks if the capacitor are charged within a timeout The following image shows the circuit which charges the capacitors cet Se es se ie ate oe ed es a eee a al RES 6 34 Pa ae ere INVERTER oe DS LA ee ee J If the charging procedure is incorrect an alarm is signalled and the main contactor is not closed Possible reasons There is an external short circuit or low resistance path between Batt connector and ground This can prevent or slow down the charge Check the cables looking for wrong connections o
21. sensor is connected between A24 and A25 ANALOG an analog motor thermal sensor like a KTY 84 is connected between A24 and A25 NONE no motor thermal sensor switch is connected In the standard configuration the controller is set to read a motor temperature sensor of the type KTY84 130 which is one of the most common sensors This setting cannot be modified by parameters Please inform Zapi if a different temperature sensor is going to be used 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 Page 41 72 lt establishes a deadband in the accelerator input curve see also curve below 4 THROTTLE X POINT This parameter changes the characteristic of the accelerator input curve 5 THROTTLE Y POINT This parameter changes the characteristic of the accelerator input curve SP a A gt gt rE gt VACC MIN and VACC MAX are values programmable by the Program Vacc function 6 ADJUSTMENT 04 This parameter determines the motor temperature level at which the Motor temperature alarm is signalled The range is from 70 C to 160 C with 10 C steps This parameter must be adjusted only if the Set temperature menu Set option parameter is programmed Analog 7 ADJUSTMENT 03 This parameter isn t used 8 ADJUSTMENT 02 It adjus
22. show the Opening Zapi Menu AFAZPOCB ADJUSTMENT BATTERY 84 0 o0 OM ARE YOU 5V SURE YES ENTER NO 0UT CONFIG ADJUST MENU MENTS ACE5 INVERTER User Manual 8 7 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 7 1 Traction The following parameters can be modified 1 ACCELERATION DELAY It determines the acceleration ramp The parameter value in seconds sets the time needed to speed up the motor from 0 to 100Hz 2 RELEASE BRAKING It controls the deceleration ramp when the travel request is released The parameter value in seconds sets the time needed to slow down the motor from 100 to OHZ 3 INVERS BRAKING It controls the deceleration ramp when the direction switch is inverted during travel The parameter value in seconds sets the time needed to slow down the motor from 100 to OHZ 4 PEDAL BRAKING It determines the deceleration ramp when the travel request is released and the brake pedal switch is closed The parameter value in seconds sets the time needed to slow down the motor from 100 to OHz 5 SPEED LIMIT BRK Deceleration ramp when the pedal position is changed but not completely released The parameter value in seconds sets the time needed to slow down the motor from 100 to OHz 6 BRAKE CUTBACK It determines the
23. solutions to improve the safety of the machine according to customer requirements Machine manufacturer holds the responsibility for the truck safety features and related approval ACES inverter electronic implements an hardware safety circuit which is able to open the Main Contactor MC 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 MC 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 MC coil and EB coil The safety circuit is also periodically checked by the microcontroller if the microcontroller detects a failure in the SAFETY circuit the microcontroller itself will bring the machine in a safe status Suggested connection of SAFETY circuit STAND ALONE CONFIGURATION it must be used only if there are other controllers that can stop the system in case of failure 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 so that the pump controller can drive the traction safety input and open the power line in case of malfunctioning of traction controlle
24. the potentiometer is not correctly calibrated Do the PROGRAM VACC procedure B the potentiometer is not correctly connected Check the cables C the potentiometer itself is defective Check the potentiometer 11 PEDAL WIRE KO The inverter continuously checks the NPOT pin to find out if the potentiometer has been disconnected Inside the NPOT circuit there is a sense diode which is on only if the potentiometer is correctly connected between PPOT and NPOT If the controller detects the diode turn off the alarm is signalled because either PPOT or NPOT are not connected anymore Controller operation is prevented while this alarm is active Check the potentiometer cables if this alarm arises If the alarm persists there is an internal failure and the controller must be replaced 12 STBY HIGH Test carried out in stand by The controller checks if the current in stand by is zero If it is non zero this alarm is activated The controller opens the MC and it inhibits machine operations Possible causes A current sensor failure B logic board failure In both cases the controller must be replaced 13 SEAT KO This alarm may be present in combi systems traction pump The pump can use one of its digital input to read the status of the SEAT switch together with the traction controller Then master and slaves compare the two read status via CAN messages The alarm is signalled if a mismatch is found Check the connection of the SEAT switch to
25. within console for checking main parameters 5 1 Diagnosis Page 20 72 The microcontroller continually monitors the inverter and carries out a diagnostic procedure on the main functions The diagnosis is different in the four main operational modes 1 Diagnosis at start up watchdog circuit current sensor capacitor charging phase s voltages contactor drives can bus interface It also checks if the switch sequence for operation is correct and if the output of accelerator unit is correct Standby diagnosis watchdog circuit phase s voltages contactor driver AFAZPOCB ACE5 INVERTER User Manual current sensor can bus interface 3 During traction watchdog circuits contactor driver current sensors can bus interface 4 Continuous diagnosis temperature of the inverter motor temperature The status of the internal diagnosis is provided in two ways 1 the digital console can be used which gives a detailed information about any failure which can be present 2 any failure code is also sent on the Can Bus to other modules for example human interface modules like displays AFAZPOCB ACE5 INVERTER User Manual Page 21 72 6 DESCRIPTION OF CONNECTORS 6 1 Connectors of the logic Traction configuration Page 22 72 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 12V 5V ENC GND PPOT SEAT FORWARD BACKWARD Positive
26. 00 if the pedal is totally pressed 0 if the pedal is released 19 HAND BRAKE The level of the Handbrake Microswitch ON GND active entry of Handbrake Switch open switch OFF VB non active entry of microswitch closed switch 20 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 21 BATTERY VOLTAGE Level of battery voltage measured at the input to the key switch 22 BATTERY CHARGE The percentage Charge level of the battery 1 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 2 FREQUENCY This is the frequency of the voltage and current supplied to the motor 3 ENCODER This is the speed of the motor expressed in the same unit of the frequency this information comes from the speed sensor 4 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 5 CURRENT RMS Root Mean Square value of the motor current 6 TEMPERATURE The temperature measured on the aluminium heat sink holding the MOSFET devices 7 MOTOR TEMPERATURE This is the temperature of the motor if the option is programmed None see chapter 8 6 it shows 0 8 ACCELERATOR The voltage of the lift potentiometer s wiper CPOT The voltage level is shown on the
27. E5 INVERTER User Manual e s TESTER description of the functions The most important input and 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 list shows these measurements 8 8 1 Traction 1 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 2 FREQUENCY This is the frequency of the voltage and current supplied to the motor 3 ENCODER This is the speed of the motor expressed in the same unit of the frequency this information comes from the speed sensor 4 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 5 CURRENT RMS Root Mean Square value of the motor current 6 TEMPERATURE The temperature measured on the aluminium heat sink holding the MOSFET devices 7 MOTOR TEMPERAT This is the temperature of the motor if the option is programmed None see chapter 8 6 it shows 0 8 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 9 FORWARD SWITCH The level of the Forward direction digital entry FW ON VB active entry of closed switch
28. EMP V BATT 5 ALARMS V MOT VMN MOT M SW TEST 6 PROGRAM PEDAL 7 MOTOR DATA ti E Er e ROLL ENTER SET BUTTONS m ne ROLL OUT SET Je O 4 A zam l 8 4 Description of Standard Console Menu The following paragraph shows the structure of the parameter menu EP Special software versions may have additional parameters and setting In this case additional documentation will be provided Page 32 72 AFAZPOCB ACE5 INVERTER User Manual 8 4 1 Traction configuration MAIN MENU HEADING PARAMETER CCELERATION DELAY Sine RELEASE BRAKING INVERS BRAKING PEDAL BRAKING SPEED LIMIT BRK BRAKE CUTBACK MAX SPEED FORW Hz MAX SPEED BACK Hz CUTBACK SPEED CURVE CUTBACK FREQUENCY CREEP MAXIMUM CURRENT BACKING SPEED BACKING TIME AUXILIARY TIME TESTER MOTOR VOLTAGE FREQUENCY Hz ENCODER Hz SLIP VALUE Hz CURRENT RMS A TEMPERATURE boj MOTOR TEMPERAT C CCELERATOR V FORWARD SWITCH ON OFF BACKWARD SWITCH ON OFF ENABLE SWITCH ON OFF SEAT SWITCH ON OFF BACKING F ON OFF BACKING B ON OF CUTBACK SWITCH ON OFF BRAKE SWITCH ON OFF EXCLUSIVE HYDRO ON OFF BRAKEPEDAL PO HAND BRAKE ON OFF VOLTAGE BOOSTER Z BATTERY VOLTAGE vV BATTERY CHARGE z SAVE PARAMETER RESTORE PARAMETER m CODE ALARMS h Nt C PROGRAM VACC VACC SETTING MIN MAX MOTOR DATA NOT AVAILABLE AFAZPOCB ACE5 INVERTER User
29. KEK apopo E EE EE 5 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 control parameter setting and obviously as 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 PARAMETER UNIT En 185 185 En E ACCELERATION DELAY RELEASE BRAKING INVERS BRAKING PEDAL BRAKING SPEED LIMIT BRK BRAKE CUTBACK MAX SPEED FORW MAX SPEED BACK CUTBACK SPEED CURVE CUTBACK FREQUENCY CREEP MAXIMUM CURRENT BACKING SPEED BACKING TIME AUXILIARY TIME w aly Rp flofoloj l x i oo jojrululuajlu ju P x WEepPeq gt Tegn wslolololo A o he o Ii Slo Un Max Sp Max AJo Nn of pa jal A IMAX w No K ajrpofajz elro A Rie jiz loj iz R L o osjojojo S ria a o a L alu Oo a ali alo 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 written RESTORE on another inverter thus allowing fast and stand
30. NTENANCE TO BE REPEATED AT TIMES INDICATED Page 72 72 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 technici
31. POCB ACE5 INVERTER User Manual 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 part MIN VACC MAX 10 0 6 4 4 12 When finished press OUT an ARE YOU SURE YES ENTER NO OUT 13 The Display will ask ARE YOU SURE 14 Press ENTER for yes or OUT for NO 7 m O MAIN MENU 15 When finished the Console shows PROGRAM VAGE 16 Press OUT again to return to the Opening Zapi ooo Menu OMO AFAZPOCB ACE5 INVERTER User Manual Page 59 72 10 ACE5 DIAGNOSTIC ALARM DESCRIPTION gt A A The ACE5 controller carries out a continuous diagnosis activity in order to detect any kind of failure In this chapter the types of alarm are listed for each alarm possible failure causes are described and a solution if available is suggested Notice that special software versions may have additional alarm codes Please ask Zapi for further information Be careful while to trying to repair a controller under alarm condition even if the alarm is quite simple Possible malfunctions and unexpected behaviour may arise In case of an alarm regarding the power section use all precautions to avoid electric hazards before accessing the live parts of the controller Always remember to discharge the capacitors and disconnect the bat
32. QUENCY Hz ADJUST BATTERY V ENCODER Hz HROTTLE O ZONE SLIP VALUE Hz THROTTLE X POINT CURRENT RMS A THROTTLE Y POINT EMPERATURE e ADJUSTMENT 04 e OTOR TEMPERATURE C ADJUSTMENT 03 w CELERATOR v ADJUSTMENT 02 0 9 FTING SWITCH ON OFF ADJUSTMENT 01 0 9 ST SPEED SWITC ON OFF LOAD HM FROM MDI ON OFF 2ND SPEED SWITCH ON OFF 3RD SPEE ITCH ON OFF 4TH SPEED SWITCH ON OFF SPEED REQ ON G TCH ON OFF VOLTAGE BOOSTER BATTERY VOLTAGE V BATTERY CHARGE SAVE PARAMETER RESTORE PARAMETER i CODE ALARMS a N C PROGRAM VACC VACC SETTING MIN MAX MOTOR DATA m NOT AVAILABLE Page 34 72 AFAZPOCB ACE5 INVERTER User Manual e Sequence for setting up the parameters 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 here following Remember to re cycle the Key Switch if you make any changes to the controller s configuration 8 5 1 Traction 5 Select the Options required See Chapter 8 6 In particular Select and set the Battery voltage Select the type of motor temperature sensor 6 Confirm correct installation of all wires Use the Console s TESTER Chapter 8 8 to assist 7 Perform the accelerator signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed on Chapter 9 4 8 Set t
33. RE function Chapter 9 2 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 a y AC5T2BF ZP1 00 1 Opening Zapi Display SEV TONA ODO a OMO 2 Press ENTER to go into the General menu em MAIN MENU 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until SAVE PARAM appears on the display DO Bod 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 keys until the second Main indicates a FREE storage facility 9 Press ENTER to commence SAVE routine eje 10 You can see the items that are being stored READING whilst the SAVE routine is happening ACCEL DELAY ECC MAIN MENU 11 When finished the Console shows SAVE PARAN AFAZPOCB ACE5 INVERTER User Manual Page 55 72 12 Press OUT to return to the Opening Zapi 0o00 Display omo 9 2 Description of Console RESTORE function Page 56 72 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
34. TE AE aaa 17 4 5 Various suggestions scream id 19 5 OPERATIONAL FEATURES o let eee es 20 5 1 AP a ei lie ti li a a aa 20 6 DESCRIPTION OF GONNEC FOROS ist ip iio 22 6 1 Connectors of the logic Traction configuration 22 6 2 Connectors of the logic Pump configuratiQN ooonoccccnnnncccccnnnnocccccononacnncnonannnnnnnnnno 24 6 3 Description of power connections na 26 Z DRAWINGS do 27 7 1 Mechanical drawing spice dicas 27 7 2 Connection drawing Traction configuration oooonnncccnnnnncccccnnnnccccccnnnnacccccnnarannn cnn 28 7 3 Connection drawing Pump configuration 29 7 4 Connection drawing Combi configuration nn 30 8 PROGRAMMING amp ADJUSTMENTS USING DIGITAL CONSOLE e nena 31 8 1 Adjustments via Console annnnna 31 8 2 Additional programming tools cocomioiisnsnrric rc 31 8 3 Description of Console 8 Connection 32 8 4 Description of Standard Console Menu 32 8 4 1 Traction configuration scott isis 33 8 4 2 Pump configuration sivi kk kn kb an tacita iden 34 8 5 Sequence for setting up the parameters 35 AFAZPOCB ACE5 INVERTER User Manual Page 3 72 10 11 12 8 5 1 MC O EE TO AE ENE a n ek ME MEAN 35 852 Po e een err er ee eee 36 8 6 OPTION and ADJUSTMENTS configuratiON oococonnccccnnnnncccccnnnnoccccnnnnnanccccnnnnncnnannno 37 861 o
35. V Aman 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 ACE5 INVERTER Copyright O 1975 2011 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 IZ AMI 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 72 AFAZPOCB ACE5 INVERTER User Manual
36. Y input circuit has an internal failure Replace the controller 24 BATTERY LOW If the BATTERY CHECK parameter is set ON a battery discharge algorithm is executed When the estimated charge level is 10 this alarm is signalled and the current is reduced to the half of the programmed level 25 WRONG SET BATT When the key is turned ON the controller check the battery voltage and verifies it is within a window around the nominal value If not the MC does not close and any operation is prevented Replace the battery with a correct battery 26 WAITING FOR NODE This warning is present on some software version The controller via CANbus waits some synchronization signal from an external module before performing a particular action for example closing the MC If this signal is not received in time the controller stays stuck in an idle state showing this warning Verify the other modules to determinate in which of them there is the problem Page 70 72 AFAZPOCB ACE5 INVERTER User Manual 11 RECOMMENDED SPARE PARTS FOR INVERTER Part number Description C16507 Protected 500 A strip Fuse C16505 Protected 355 A strip Fuse C16500 10A 20 mm Control Circuit Fuse C29509 SW 200 80 V Single Pole Contactor C29532 SW 200 48 V Single Pole Contactor C12532 Ampseal Connector 35 pins Female C12796 Female Ampseal pin harness side AFAZPOCB ACE5 INVERTER User Manual Page 71 72 12 PERIODIC MAI
37. a signal from a braking pedal proportional braking The external device should be in a 3 wire Potentiometer value should be in the 0 5 10 kohm range Generally the load should be in the 1 5 mA to 30 mA range The CPOTB signal range is from 0 to 10 V 2 Electric motors very often have a thermal sensor which can be digital on off sensor normally closed or analog These sensor are 2 wire components in the majority of cases AFAZPOCB ACE5 INVERTER User Manual In case the sensor is present it can be connected between the signal input PTHERM A25 and NTHERM A24 See also chapter 8 4 for more explanation EP Analog motor temperature sensors must be configured via software Please contact Zapi technicians for more details 3 5 Speed feedback The motor control is based upon the motor speed feedback The speed transducer is an incremental encoder with two phases 90 degrees shifted The encoder can be of different types power supply 5Vor 12V electric output open collector NPN or PNP push pull line driver standard A and B or differential A A B 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 AC5T2D ZP1 13 That means AC5T AC 5 traction controller AC5P AC 5 pump controller 2 motor s poles pair n
38. age on the console Parameters modified and optimized on one unit can be stored by the console SAVE and then written RESTORE on another inverter thus allowing fast and standardized settings see console manual for details Flow Chart showing how to make Programme changes using Digital Console 1 Opening Zapi Display 2 Press ENTER to go into the General Menu 3 The Display will show 4 Press ENTER to go into the Parameter Change facility 5 The Display will show the first parameter 6 Press either ROLL UP and ROLL DOWN to display the next parameter 7 The names of the Parameter appears on the Display 8 When the desired Parameter appears the Display will show a Level Number that will be Between 0 and 9 Press either PARAM Top Right or SET Bottom Right buttons to change the Level 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 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 13 The Display will show ACST2BF ZP1 00 BOV 1000A 00000 oe gim o Ed MAIN MENU PARAMETER GHANGE O O E O E 4 oo BO RELEASE BRAKING LEVEL 5 RELEASE BRAKING LEVEL 6 GO 4d OMO ARE YOU SURE YES ENTER NO OUT MAIN MENU PARAMETER GHANGE AFAZPOCB AC
39. alf its max value This is an internal failure replace the controller 21 MOT TH SENSOR KO This test is performed if the thermal sensor is analog the range of the sensor is always checked and a warning is signalled if it is out of range When this happens the motor current is reduced to half its max value Check the integrity of the sensor and of its connections If the sensor is ok and the alarm persists the controller must be replaced 22 CAN BUS KO The diagnosis of the CAN BUS line is present only if the inverter uses this link it depends on the software version It is signalled when the inverter does not receive any message from the CAN BUS line Possible causes are e CAN wiring disconnected or damaged check them e Failure inside the external module which has to send the messages that the inverter is waiting Check any module connected via CANbus There is a problem inside the logic board replace the controller 23 SAFETY This alarm is signalled when the SAFETY input is open The SAFETY circuit gets active and opens via hardware control the drivers of MC and EB Moreover any function of the controller is stopped This could happen because e This pin is not connected to ground level single controller configuration Check the wires e Another module has deactivated the output which holds the SAFETY input at low level master slave configuration Check the module and the connection between controllers e The SAFET
40. ameter is request is also sent to the pump elapsed the truck comes down inverter by the can bus link very slowly till the flat is reached It drives the coil of an hydraulic The truck is not electrically hold EXCL OFF Steering contactor on a slope but comes down HYDRO The hydraulic steering function Very slowly till the flat is request is also sent to the pump reached inverter by the can bus link 8 6 2 Pump AFAZPOCB ACE5 INVERTER User Manual Using the CONFIG menu of the programming console the user can configure the following functions SUBMENU SET OPTIONS 1 HOUR COUNTER RUNNING the counter registers travel time only KEYON the counter registers when the key switch is closed 2 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 complete 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 3 SET TEMPERATURE DIGITAL a digital ON OFF motor thermal
41. an finds any situation 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 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 AFAZPOCB ACE5 INVERTER User Manual
42. ardized settings see console manual for details 8 7 2 Pump The following parameters can be modified 1 ACCELER DELAY It determines the acceleration ramp The parameter value in seconds sets the time needed to speed up the motor from 0 to 100Hz 2 DECELER DELAY It controls the deceleration ramp when the pump request is released The parameter value in seconds sets the time needed to slow down the motor from 100 to OHZ Page 48 72 AFAZPOCB ACE5 INVERTER User Manual 3 MAX SPEED UP lt determines the maximum lifting speed with a potentiometer control 4 MIN SPEED UP It determines the minimum lifting speed with a potentiometer control when the lifting enable switch is closed nut the lift potentiometer is at its minimum 5 CUTBACK SPEED Speed reduction percentage of the max speed when the cutback switch is active 6 1ST SPEED FINE Speed in Hz which is set when the First speed request is activated It is can be regulated with a 1Hz precision 7 2ND SPEED FINE Speed in Hz which is set when the Second speed request is activated It is can be regulated with a 1Hz precision 8 3RD SPEED FINE Speed in Hz which is set when the Third speed request is activated It is can be regulated with a 1Hz precision 9 4TH SPEED FINE Speed in Hz which is set when the Fourth speed request is activated It is can be regulated with a 1Hz precision 10 HYD SPEED FINE Speed in Hz which is set when t
43. are Material Handling counterbalanced with load larger than 5 tons GSE and push tractors AFAZPOCB ACE5 INVERTER User Manual Page 5 72 2 SPECIFICATION 2 1 ACE5 technical specifications Inverter for AC asynchronous 3 phase motors Regenerative braking functions Can bus interface Digital control based upon a microcontroller ple lo A PP ae A taa ENA 36 48 V 72 80 V 96 V 120V Maximum current 36 48 V ooo eeeeecceeeeseeeeeeeeeeeneeeeeeeeeeeeeeeeeeeees 1000 A RMS for 2 Maximum current 72 80 V eeeeeccceeeesccceeeeseaeeeeeenneeeeeeeeeeeees 1000 A RMS for 2 Maximum current 96 V aus la 800 A RMS for Maximum current 120 Vision caka kla ka i beno boka pas pake 750 A RMS for Operating TEGUBNOV sin vite ka pie apik pei ie eden e A ie 8 kHz External temperature range cccooccccnnonoccccnnnonccononnannccnnnnnnnncnnnnnnanannnns 30 C 40 C Maximum inverter temperature at full power 75 C 2 2 Block diagram Page 6 72 AFAZPOCB ACE5 INVERTER User Manual 3 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT The ACES inverter need some external parts in order to work The following devices complete the kit for The following devices complete the kit for the installation in a typical application EP The use of special devices to be connected to the inverter has to discussed with Zapi Technicians 3 1 Main contactor T
44. arry hundreds of Amperes there are voltage drops due to the impedance of the cables and this 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 1 Module The red lines are can wires Page 12 72 AFAZPOCB ACE5 INVERTER User Manual The black boxes are different modules for example traction controller pump controller and a display connected by canbus The black lines are the power cables This is apparently a good layout but can bring to errors in the canbus 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 A Correct Layout Module 2 Module 3 Note Module 1 power gt Module 2 power gt Module 3 power 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 and a pump motor controller and a third module works with less current the best way to deal this configuration is to create a common ground point star configuration A Correct Layout Module 1 Module 2 Center of the Ground connection Module 3 Note Module 1 power l
45. articularly 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 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 AFAZPOCB ACE5 INVERTER User Manual Page 19 72 5 OPERATIONAL FEATURES Speed control 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 machine is electrically hold on a slope for a programmable time see also chapter 8 6 Stable speed in every position of the accelerator Regenerative release braking based upon deceleration ramps Regenerative braking when t
46. ative 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 Page 25 72 6 3 Description of power connections View of the power bars A GO fa Page 26 72 Negative of the battery Positive of the battery Connection bars of the three motor phases follow this sequence and the indication on the motor AFAZPOCB ACE5 INVERTER User Manual 7 DRAWINGS 7 1 Mechanical drawing
47. attery discharge table 11 ADJUSTMENT 01 It adjusts the upper level of the battery discharge table A 12 LOAD HM FROM MDI For an explanation of this point see the MDI instrument handbook 13 CHECK UP DONE Turn it On when the asked Maintenance service has been executed to cancel the CHECK UP NEEDED warning 14 CHECK UP TYPE This parameter set up a Maintenance hour counter It specifies the handling of the CHECK UP NEEDED warning NONE No CHECK UP NEEDED warning AFAZPOCB ACE5 INVERTER User Manual Page 39 72 OPTION 1 CHECK UP NEEDED warning on the hand set after 300 hours OPTION 2 Equal to OPTION 1 but performances are reduced down to 50 after 340 hours OPTION 3 Equal to OPTION 2 but the truck definitively stops after 380 hours 15 PWM ON MAIN CONT OFF the inverter applies the battery voltage to the loads on the main contactor coil ON the PWM reduces the voltage at the loads on the main contactor coil down to 62 of the battery voltage 16 PWM ON AUX OUT OFF the inverter applies the battery voltage to the loads on the auxiliary output ON the PWM reduces the voltage at the loads on the auxiliary output down to 62 of the battery voltage STOP ON RAMP STRATEGIES AUX STOP OUTPUT ON A28 OUTPUT BEHAVIOUR ON A SLOPE RAMP It drives the coil of an The truck is electrically hold on a electromagnetic brake slope when the time set by The hydraulic steeri
48. attery voltage and verifies it is within a window around the nominal value If not the MC does not close and any operation is prevented Replace the battery with a correct battery 30 WAITING FOR NODE This warning is present on some software version The controller via CANbus waits some synchronization signal from an external module before performing a particular action for example closing the MC If this signal is not AFAZPOCB ACE5 INVERTER User Manual Page 65 72 received in time the controller stays stuck in an idle state showing this warning Verify the other modules to determinate in which of them there is the problem 10 2 Analysis of alarms for Pump controller 1 WATCH DOG The test is made in both running operation and in stand by It is a self diagnosing test within the electronic board If an alarm should occur the controller must be replaced 2 EEPROM KO Fault in the area of memory in which the adjustment parameters are stored this alarm inhibits machine operation If the defect persists when the key is switched OFF and ON again replace the logic If the alarm disappears remember that the parameters stored previously have been cancelled and replaced by the default values 3 LOGIC FAILURE 1 This alarm signals that an undervoltage overvoltage protection operation has occurred This alarms stops the controller operation and opens the MC Two possible reasons A Areal undervoltage overvoltage situa
49. both master and slave If no failure is found the problem is internal to the controller 14 DATA ACQUISITION This alarm is signalled in the current gain acguisition phase Wait the end of the acguisition activity The gain acquisition test can be carried out only by Zapi personnel or other trained technicians 15 MAIN CONTACTOR ALARMS In the combi system pump traction the main contactor is driven by the traction inverter So the following description concerns the pump inverter when used independently from the traction inverter In this configuration the pump inverter manages its own main contactor Notice that all of these alarm cause the opening of the MC and the stop of all functions of the controller DRIVER SHORTED When the key is switched ON the controller checks that the NMC pin is not at zero voltage If it is this alarm is signalled MC stay open and any function is prevented Possible causes are e Driver inside the NMC circuit is shorted The controller has to be replaced e An external short is present between NMC and ground Check the cables AFAZPOCB ACE5 INVERTER User Manual CONTACTOR DRIVER When all initial diagnoses are finished the traction logic tries to closes the MC by activating the NMC driver NMC voltage is pulled towards Batt voltage If the voltage at the NMC pin does not become low this alarm is signalled and any function is prevented This alarm is caused by an internal failure the contr
50. ctivating the NMC driver NMC voltage is pulled towards Batt voltage If the voltage at the NMC pin does not become low this alarm is signalled and any function is prevented This alarm is caused by an internal failure the controller must be AFAZPOCB ACE5 INVERTER User Manual Page 63 72 Page 64 72 replaced CONTACTOR OPEN The main contactor coil has been driven by the logic board NMC has become low but the contactor does not close Any function is prevented Two possible reasons A the MC coil is damaged or it is rated to a voltage larger than the voltage applied Check the coil B the two contacts of the contactor are not properly working and they cannot close Check them CONTACTOR CLOSED AT start up the controller checks if the MC contact is already closed when the coil isn t driven yet The test is carried out by trying to discharge the capacitor bank If they don t discharge the failure condition is entered and any function is prevented It is suggested to check the contactor contacts in particular if they are mechanically stuck or pasted Notice that this test isn t carried out if at start up the capacitor are completely discharged 19 AUX OUTPUT KO The controller checks the driver inside the NEB pin If the status of the driver output does not correspond to the signal coming from the microcontroller this alarm is signalled MC opens and all function are stopped Possible causes are e Presence of
51. e pedal is pushed brake switch closed the inverter performs an electrical braking following Pedal braking parameter 8 SET TEMPERATURE DIGITAL a digital ON OFF motor thermal sensor is connected between A24 and A25 ANALOG an analog motor thermal sensor like a KTY 84 is connected NONE no motor thermal sensor is connected In the standard configuration the controller is set to read a motor temperature sensor of the type KTY84 130 which is one of the most common sensors This setting cannot be modified by parameters Please inform Zapi if a different temperature sensor is going to be used 9 AUX FUNCTION ON OFF _ if this option is programmed ON the traction inverter applies maximum braking and traction torque 10 ENABLE FUNCTION PRESENT A7 input is managed as accelerator enable input ABSENT A7 input is managed as exclusive hydro input ne CHECK PUMP HYDRO ON OFF if ON it turns on the diagnosis of the CAN communication to a pump module In this case if the traction inverter doesn t receive any messages by the pump inverter from the CAN BUS line the CAN BUS KO warning appears on the traction and the maximum speed is reduced down to 10 The traction also checks via CAN that there aren t alarms in the pump If pump is in alarm the maximum speed is reduced down to 10 SUBMENU ADJUSTMENTS 1 SET POT BRK MIN lt records the minimum value of braking pedal potentiometer when the braking pedal switc
52. e 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 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 whom the machine has to be exposed to These tests are carried out at determined levels of electromagnetic fields to simulate external undesired disturbances and verify the electronic devices response 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 A 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 where serial communications canbus are spread everywhere on the truck and carry critical information B inthe worst case and when the amount of charge is very high the discharge process can det
53. ends on the AUX OUTPUT 1 option setting see also the table at the end of this paragraph OFF the stop on ramp feature is not performed 6 AUX OUTPUT 1 BRAKE A28 output drives an electromagnetic brake coil see also the table below HYDRO CONT the inverter manages an hydraulic steering function when the direction input or brake pedal input are active or a movement of the truck is detected EX HYDRO the inverter manages an hydraulic steering function when the exclusive hydro input is active 7 PEDAL BRAKING ANALOG The mechanical brake pedal has a switch and a potentiometer installed When the accelerator is released and the pedal brake is pushed the inverter performs an electrical braking whose intensity is proportional to the brake pedal potentiometer The minimum intensity is established by the Release braking parameter when the brake pedal is slightly pressed brake switch close but brake potentiometer at the minimum The maximum intensity is established by the Pedal braking parameter when the brake pedal is fully pressed brake potentiometer at the maximum In the middle positions the electrical braking intensity is a linear function between minimum and maximum intensity DIGITAL The truck does not have a potentiometer installed on the mechanical brake pedal but only a microswitch when the accelerator AFAZPOCB ACE5 INVERTER User Manual Page 37 72 Page 38 72 pedal is released and the brak
54. ermine failures in the electronic devices the type of failure can vary from an intermittently malfunction to a completely failure of the electronic device 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 A SOURCE OF EMISSIONS finding the main source of disturb and work on it B SHIELDING enclosing contactor and controller in a shielded box using shielded cables C 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 AFAZPOCB ACE5 INVERTER User Manual 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 ELECTROSTATIC IMMUNITY Three ways can be followed to prevent damages from ESD A PREVENTION when handling ESD sensitive electronic parts ensure the operator is grounded test grounding devices on a daily basis for correct functioning this precaution is p
55. ether 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 is much higher 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 4 3 Hardware protection and safety features A 4 3 1 Protection features ACES is protected against some controller injuries and malfunctions Page 16 72 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 75 C the maximum current is reduced in proportion to the increase of temperature At 100 C the motor current is reduced to zero The temperature can never exceed 100 C External agents The inverter is protected against dust and the spray of liquid to a degree of protection meeting IP65 Protection against accidental Start up A precise sequence of operations are necessary before the machine w
56. ey switch see connection diagrams Typical fuse rating is 6 3 10A and the voltage must be the same as the battery voltage 4 1 3 Fuse for power section We suggest to place a fuse to protect the power cables Normally this fuse is placed in the cable carrying the positive of the battery see connection diagrams The fuse rating depends on the average current of a typical operating cycle of the application and not on the controller current In case a single fuse is not enough for the application two fuses in parallel can be used for example 2x355A instead of a single 700A fuse The majority of applications should be covered by fuses in the range 500 700A The voltage rating must be the same or larger as the battery voltage EP Notice that the purpose of the power fuse is not to protect the power section of the inverter In case of short circuit a damage in the inverter will occur too quickly and the fuse will not blow The purpose of the fuse is to protect the power cables Page 10 72 AFAZPOCB ACE5 INVERTER User Manual A in case the operating current rises too much For Safety reasons we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blows fa Installation of the hardware A Before doing any operation ensure that the battery is disconnected When all the installation is completed start the machine with the drive wheels raised from the floor to ensure that an
57. ge Common of FW BW SR PB SEAT BACK FW BACK BW EXCLUSIVE HYDRO ENABLE microswitches This input allows the customer to select the software for traction or lifting application Configuration Open not connected it is a Traction inverter Closed connected with A35 it is a pump inverter Brake potentiometer positive It is the same voltage as A3 Keep load gt 1 kQ Connected to the power supply through a microswitch with a fuse in series It is a ground reference It is a ground reference Positive serial reception 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 Page 23 72 6 2 Connectors of the logic Pump configuration Page 24 72 A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 A13 A14 A15 A16 A17 A18 A19 A20 A21 A22 A23 A24 A25 A26 12V 5V ENC GND PPOT 4 TH LIFT ENABLE 1ST DIG IN 3 RD 2ND HYDRO SR SAFETY ENC A ENC B NPOT CPOT CAN T CAN H CAN L NPOT AUX CPOT AUX ENC A ENC B NTHERM PTHERM NAUX Positive of encoder power supply 5V or 12V output The output voltage must be configured by Zapi there is an internal jumper Negative of encoder power supply Lift potenti
58. h 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 lt records the maximum value of braking pedal potentiometer when the braking pedal is fully pressed 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 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 AFAZPOCB ACE5 INVERTER User Manual VACC MIN and VACC MAX are values programmable by the Program Vacc function 8 ADJUSTMENT 04 This parameter determines the motor temperature level at which the Motor temperature alarm is signalled The range is from 70 C to 160 C with 10 C steps This parameter must be adjusted only if the Set temperature menu Set option parameter is programmed Analog 9 ADJUSTMENT 03 This parameter isn t used 10 ADJUSTMENT 02 It adjusts the lower level of the b
59. he MAXIMUM CURRENT Current using the table on Chapter 8 7 9 Set the Acceleration Delay requirements for the machine Test the parameters in both directions 10 Set the FREQUENCY CREEP level starting from level 0 6 Hz The machine should just move when the accelerator microswitch is closed Increase the Level accordingly 11 Set the Speed Reductions as required Make adjustments to CUTBACK SPEED parameter Check the performance with the accelerator pedal totally depressed If the machine is a forklift check the performance with and without load 12 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 13 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 14 PEDAL BRAKING If used Operate the machine at full Speed Release the accelerator pedal and press the Pedal Brake Set braking level to your requirements 15 Set MAX SPEED FORW 16 Set MAX SPEED BACK Reverse 17 Make the choice for the truck behaviour on a slope see chapter 8 4 If the Stop
60. he Console displays AFSTOBF PARAM 14 Press OUT to return to the Opening Zapi Display 9 3 Description of ALARMS menu The microprocessor in the controller remembers the last five Alarms that have occurred ltems remembered relative to each Alarm are 1 the code of the alarm 2 the number of times the particular Alarm occurred 3 the Hour Meter count when the first alarm event has occurred 4 the controller temperature of the first alarm event This function permits a deeper diagnosis of problems as the recent history can now be accessed If an alarm is continuously happening the controller does not use new memory of the logbook but it just updates the memory cell about that particular alarm Flow Chart showing how to use the ALARMS function via the Digital Console ACST2BF ZP1 00 BOV 1000A 00000 1 Opening Zapi Display 2 Press ENTER to go into the General menu z a MAIN MENU 3 The Display will show PARAMETER CHANGE 4 Press ROLL UP or ROLL DOWN button until PARAMETER CHANGE appears on the display 5 The Display will show 6 Press ENTER to go into the ALARMS function 7 The Display will show the most recent Alarm 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 AFAZPOCB ACE5 INVERTER User Manual Page 57 72 10 When you have
61. he 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 1 traction inverter the traction inverter sends a hydraulic steering function request to the pump inverter on the can bus line see also Chapter 8 6 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 pin A28 see also Chapter 8 6 2 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 Self diagnosis 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
62. he hydraulic steering request is activated It is can be regulated with a 1Hz precision 11 MAXIMUM CURRENT This parameter changes the maximum current of the inverter It is a percentage of the current defined by factory settings 12 AUXILIARY TIME Time delay before switching off the hydraulic steering function after the hydraulic steering request has been deativated The following table shows the different values at which the parameters can be set ii PROGRAMMED LEVEL opa fz fspafspfo 7 s o MaxsreeDur m pe 0 95 ao ios a0 155 170 as 20 fun sree ar o as iso ies 50 195 210225 oso ass comas mas ujo slejslsjs s ls a Perman e Pp fauxiiarytime se o o2 oa ox ro sms To so The acceleration time shown is the time from 0 Hz to 100 Hz maximum selectable speed This is the ideal ramp 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 The deceleration time shown in the table is the time from 100 Hz to 0 Hz This is the ideal ramp 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 AFAZPOCB ACE5 INVERTER User Manual Page 49 72 Page 50 72 Adjustable with a 1 Hz resolution in the 0 to 200 Hz range After changing a parameter press ENTER to confirm data when requested by the mess
63. he input to the key switch 18 BATTERY CHARGE The percentage Charge level of the battery AFAZPOCB ACE5 INVERTER User Manual Page 53 72 Flow Chart showing how to use the TESTER function of the Digital Console eee ACST2BF ZP1 00 1 Opening Zapi Display 80V 1000A 00000 EES Mimi 2 Press ENTER to go into the General menu Zan 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 MOTOR 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 Press 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 Page 54 72 AFAZPOCB ACE5 INVERTER User Manual 9 OTHER FUNCTIONS 9 1 Description of Console SAVE function The SAVE function allows the operator to transmit the Parameter values and Configuration data of the controller into the Console memory It is possible to load 16 different programmes The information saved in the Console memory can then be reloaded into another inverter using the RESTO
64. he main contactor is a component of extreme importance for electrical safety It must be installed See connection diagram for more details The coil of the main contactor has to be connected between the pins PMC A27 and NMC A26 It can be driven in two ways on off control the coil is driven with the full battery voltage the coil is switched at high frequency 1 kHz with a duty cycle around 60 this feature is useful to decrease the power dissipation of the contactor coil Each coil has a preferred way which has to be used to energize it The ACE5 supports both driving methods a software parameter can switch between on off control and switching control 3 2 Microswitches The microswitches must have a contact resistance lower than 0 1 ohm and a leakage current lower than 100 pA Under maximum load 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 forward request is made Microswitches are used to send digital signals and thus are typically connected to digital inputs 3 3 Accelerator unit The accelerator unit can consist of a potentiometer or an Hall effect device It should be in a 3 wire configuration typically positive supply negative supply and signal The main analog input CPOT A16 Ampseal connector version can read signals ranging from 0 to 10 V Potentiometer value
65. he motor is cold check the wiring If the wires are ok replace the controller 23 THERMIC SENSOR KO The range of internal temperature sensor is always checked and a warning is signalled if it is out of range When this happens the motor current is reduced to half its max value This is an internal failure replace the controller AFAZPOCB ACE5 INVERTER User Manual 24 MOT TH SENSOR KO This test is performed if the thermal sensor is analog the range of the sensor is always checked and a warning is signalled if it is out of range When this happens the motor current is reduced to half its max value Check the integrity of the sensor and of its connections If the sensor is ok and the alarm persists the controller must be replaced 25 CAN BUS KO The diagnosis of the CAN BUS line is present only if the inverter uses this link it depends on the software version lt is signalled when the inverter does not receive any message from the CAN BUS line Possible causes are e CAN wiring disconnected or damaged check them e Failure inside the external module which has to send the messages that the inverter is waiting Check any module connected via CANbus e There is a problem inside the logic board replace the controller 26 SAFETY This alarm is signalled when the SAFETY input is open The SAFETY circuit gets active and opens via hardware control the drivers of MC and EB Moreover any function of the controller is stopped
66. ill start Operation cannot begin if these operations are not carried out correctly Any requests for drive must be made after closing the key switch Low battery charge When the battery charge is low the maximum current is reduced to the half of the maximum current programmed Wrong battery The controller checks if the battery has a wrong nominal voltage for example if a 120V battery is connected to a 80V inverter In case a wrong battery is detected the main contactor is not closed to prevent damage to the power section Transient overvoltage and undervoltage During operation the battery voltage can vary a lot If a lot of current is absorbed the battery voltage will drop while during regenerative braking it will increase An hardware protection deactivates the power section and opens the main contactor in case of large over and undervoltages See the description of the alarm LOGIC FAILURE 1 in Chapter 10 AFAZPOCB ACE5 INVERTER User Manual 4 3 2 Safety features A ZAPI controllers are designed according to the prEN954 1 and EN13849 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
67. ng function henna pei e P request is sent to the pump C apsed ine Drage IS appiec an BRAKE ON inverter by the can bus link the 3 phase bridge is released Do not use this combination if the negative brake is not installed It drives the coil of an The truck is not electrically hold electromagnetic brake on a slope but comes down The hydraulic steering function very slowly when the time set inverter by the can bus link elapsed the brake is applied BRAKE OFF and the 3 phase bridge is opened Do not use this combination if the negative brake is not installed It drives the coil of an hydraulic The truck is electrically hold on a HYDRO steering contactor slope when the time set by CONT ON The hydraulic steering function auxiliary time parameter is request is also sent to the pump elapsed the truck comes down inverter by the can bus link very slowly till the flat is reached It drives the coil of an hydraulic The truck is not electrically hold HYDRO OFF Steering contactor on a slope but comes down CONT The hydraulic steering function Very slowly till the flat is request is also sent to the pump reached inverter by the can bus link Page 40 72 AFAZPOCB ACE5 INVERTER User Manual It drives the coil of an hydraulic The truck is electrically hold on a EXCL ON _ Steering contactor slope when the time set by HYDRO The hydraulic steering function auxiliary time par
68. nnector pin assignment see the chapter description of the connectors 4 2 5 Connection of the encoder 1 ACE5 supports different types of encoder To control an 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 A1 positive of encoder power supply A2 negative of encoder power supply A13 phase A of encoder A22 phase A inverted encoder with differential output A14 phase B of encoder A23 phase B inverted encoder with differential output 2 Connection of encoder with differential outputs 5 V power supply Page 14 72 AFAZPOCB ACE5 INVERTER User Manual 3 Connection of encoder with open collector output 5 V power supply 4 Connection of encoder with open collector output 12 V power supply A VERY IMPORTANT When ordering the controller It is necessary to specify to Zapi the type of encoder used power supply electronic output and n of pulses for revolution In fact the logic unit must be set in the correct way by Zapi 4 2 6 Main contactor and key connection The connection of the main contactor can be carried out following the following drawing a le e poo If a mechanical battery line switch is installed it is necessary that the key AFAZPOCB ACE5 INVERTER User Manual Page 15 72 supply to the inverter is open tog
69. nu AGST2BF ZP1 00 BOV 1000A 00000 1 Opening Zapi Menu 2 Press Top Left amp Right Buttons to enter CONFIG NOM Menu poo 3 The display will show SET MODEL ers 4 Press ROLL UP or ROLL DOWN button until NOG ADJUSTMENTS Menu appears Dou 5 ADJUSTMENTS appears on the display es 6 Press ENTER to go into the ADJUSTMENTS a Menu poo 3 A BATTERY TYPE 7 The display will shows SET BATTERY TYPE pw 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 ano 12 Press ENTER to confirm m o 13 Repeat the same from 5 to 12 points for the other adjustments Page 44 72 AFAZPOCB ACE5 INVERTER User Manual Flow chart showing how to use the SET BATTERY TYPE adjustment 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 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 no
70. of an overcurrent event the NMC and ENB drivers are stopped and this alarm is raised Look for short circuit in parallel with the MC and EB coils or if these coils have the correct impedance If no short is present and the alarm persists the failure is internal to the controller which must be replaced The overcurrent detection circuit is checked at start up too If this test fails the alarm is raised In this case the failure is only internal to the logic board and the controller must be replaced 18 HIGH TEMPERATURE This is a warning and not an alarm It indicates that the controller temperature is greater than 75 C The maximum current is reduced proportionally to the temperature increase The controller current drops to zero at 100 C If the alarm is signalled when the controller is cold there is an internal failure and the controller must be replaced 19 MOTOR TEMPERATURE This warning is signalled if the motor temperature switch opens digital sensor or if the analog signal overtakes the cut off level defined by ADJUSTMENT 4 parameter The motor current is reduced to avoid any damage to the motor If it happens when the motor is cold check the wiring AFAZPOCB ACE5 INVERTER User Manual Page 69 72 If the wires are ok replace the controller 20 THERMIC SENSOR KO The range of internal temperature sensor is always checked and a warning is signalled if it is out of range When this happens the motor current is reduced to h
71. oller must be replaced CONTACTOR OPEN The main contactor coil has been driven by the logic board NMC has become low but the contactor does not close Any function is prevented Two possible reasons A the MC coil is damaged or it is rated to a voltage larger than the voltage applied Check the coil B the two contacts of the contactor are not properly working and they cannot close Check them CONTACTOR CLOSED AT start up the controller checks if the MC contact is already closed when the coil isn t driven yet The test is carried out by trying to discharge the capacitor bank If they don t discharge the failure condition is entered and any function is prevented It is suggested to check the contactor contacts in particular if they are mechanically stuck or pasted Notice that this test isn t carried out if at start up the capacitor are completely discharged 16 AUX OUTPUT KO The controller checks the driver inside the NEB pin If the status of the driver output does not correspond to the signal coming from the microcontroller this alarm is signalled MC opens and all function are stopped Possible causes are e Presence of external shorts or misconnections Check the EB coil wire e There is an internal failure Replace the controller 17 COIL SHORTED Inside the logic board there is a shunt in common with both the NMC and the NEB output drivers This shunt is used to detect overcurrent conditions in these outputs in case
72. ometer positive 5V or 12 V output The output voltage must be configured by Zapi there is an internal jumper Keep load gt 1 ko Fourth speed input it must be connected to the 4th speed microswitch It is active high Request input for potentiometer controlled lifting it must be connected to the lift enable microswitch It is active high First speed input it must be connected to the 1st speed microswitch It is active high Free digital input input It is active high Third speed input it must be connected to the 3rd speed microswitch It is active high Second speed input it must be connected to the 2nd speed microswitch It is active high Hydraulic steering request input It is active high Speed reduction input it must be connected to the speed reduction switch It is active low switch opened If not connected to Batt the MC coil power output will be disabled Phase A of encoder Phase B of encoder Negative of lift unit This pin is tested for wire disconnection diagnosis Analog input for lift potentiometer wiper CAN termination connect to CAN H A18 to insert 1200 CAN termination resistance High level CAN BUS voltage I O Low level CAN BUS voltage I O It is a ground reference Free analog input Phase A inverted of encoder encoder with differential output Phase B inverted of encoder encoder with differential output It is a ground reference Input for motor temperature sensor
73. pending on the motor used it is necessary to set some parameters giving Zapi the motor curves it is possible to know the optimal setting in order to the motor runs efficiently AFAZPOCB ACE5 INVERTER User Manual e OPTION and ADJUSTMENTS configuration 8 6 1 Traction Using the CONFIG MENU of the programming console the user can configure the following functions see OPERATIONAL FEATURE chapter for an explanation of hydraulic steering function SUBMENU SET OPTIONS 1 HOUR COUNTER RUNNING the counter registers travel time only KEYON the counter registers when the key switch is closed 2 BATTERY CHECK ON the battery discharge level check is carried out when the battery level reaches 10 an alarm is activated 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 3 CUTBACK MODE PRESENT AQ input is managed as a cutback speed input ABSENT A9 input is managed as an handbrake input 4 HYDRO KEY ON ON OFF if this option is programmed ON the traction inverter manages an hydraulic steering function when the key is switched ON only if the aux output 1 option is programmed as hydro contactor or as exclusive hydro 5 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 dep
74. r fa 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 AFAZPOCB ACE5 INVERTER User Manual Page 17 72 Page 18 72 5 The study of the emission problems disturbances generated by the device and the possible countermeasure to prevent the propagation of that energy Different cases are a conduction issues when guiding structures such as wires and cables are involved b radiated emissions issues when electromagnetic energy propagates through the open space In our case the origin of the disturbances is the switching of the mosfets which are working at high frequency and generate RF energy Wires and cables have the key role to propagat
75. r cable dispersions to ground The charging circuit has a failure for example the charging resistor is opened In this case the controller must be replaced There is a failure on the power modules which interfere with the capacitor charging The controller must be replaced Notice that this test is not carried out if the capacitor are already charged when you switch on the controller 9 VMNLOW VMN HIGH The test is carried out during initial diagnosis and in stand by when the phase voltages has to be about half the voltage on the power capacitors with MC closed each phase voltage is about half of the battery voltage An alarm condition is detected if a phase voltage is too close to ground VMN LOW or to battery voltage VMN HIGH The MC is opened and the controller is stopped if this alarm arises Possible causes A problem with the motor connections or the motor power circuit check if the 3 phases are correctly connected check if there s a dispersion of the motor towards ground or towards battery B failure inside the inverter power stage replace it 10 VACC NOT OK The test is made in stand by when pump is not enabled yet This alarm says that the voltage of the lift potentiometer is 1 V greater than the minimum value programmed by the PROGRAM VACC function Unless this alarm is removed any pump request will be ignored AFAZPOCB ACE5 INVERTER User Manual Page 67 72 Page 68 72 Possible causes A
76. rnal voltage thresholds which depend on the nominal battery voltage The list of these thresholds is the following e 36V 48V undervoltage 15V overvoltage 65V e 80V undervoltage 30V overvoltage 115V e 96V undervoltage 34V overvoltage 125V e 120V undervoltage 40V overvoltage 152V LOGIC FAILURE 2 Fault in the hardware section of the logic board which reads the feedback signals of the phase s voltages This alarms stops the controller operation and opens the MC The controller must be replaced LOGIC FAILURE 3 Fault in the hardware section of the logic board which manages the hardware current protection This alarms stops the controller operation and opens the MC The controller must be replaced CHECK UP NEEDED This is a warning not a real alarm It is an information for the user that the programmed time for maintenance is elapsed INCORRECT START This alarm signals an incorrect starting sequence Possible causes A microswitch failure B error in sequence made by the operator C incorrect or defective wiring Check all external cables and devices controlling the starting sequence In case the failure persists replace the controller FORW BACK An alarm is signalled when a double running request is made simultaneously both forward and backward directions are selected Possible causes A microswitch failure B error in seguence made by the operator C incorrect or defective wiring Check all external cables and devices cont
77. rolling the selection of the travel direction In case the failure persists replace the controller HANDBRAKE The truck does not start because the handbrake switch is opened Possible causes A microswitch failure B error in sequence made by the operator C incorrect or defective wiring Check the handbrake cable and switches In case the failure persists replace the controller 10 ENCODER ERROR Two consecutive readings of the encoder speed are too much different because of the inertia of the system it is not possible the encoder changes its speed a lot in a short period The alarm is set to appear if the read speed changes of more than 40 Hz in few milliseconds This alarm stops the power bridge Possible causes an encoder failure has occurred e g one or two channels of the encoder are corrupted or disconnected Check both the electric and the mechanical encoder functionality the electromagnetic noise on the sensor bearing disturbs the encoder AFAZPOCB ACE5 INVERTER User Manual Page 61 72 signal This event is quite common at low speed and very high motor currents when the bearing is not shielded the truck has encountered an high step or a wide hole on the road The abnormal movement of the wheel may trigger this alarm 11 CAPACITOR CHARGE When the key is switched ON the inverter tries to charge the internal capacitor bank through a power resistance and it checks if the capacitor are charged within a timeou
78. should be in the 0 5 10 kohm range generally the load AFAZPOCB ACE5 INVERTER User Manual Page 7 72 should be in the 1 5 mA to 30 mA range Faults can occur if it is outside this range 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 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 KRG 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 4 Other analog control devices Page 8 72 Other devices whose output is an analog signal can be connected to the inverter 1 Input CPOTB A21 Ampseal connector is an analog input whose typical application is is another analog input whose typical application is for reading
79. t The following image shows the circuit which charges the capacitors NA T E AE SE EJ AAA 7 RES 6 34 e on bo INVERTER li ee ET SS J If the charging procedure is incorrect an alarm is signalled and the main contactor is not closed Possible reasons There is an external short circuit or low resistance path between Batt connector and ground This can prevent or slow down the charge Check the cables looking for wrong connections or cable dispersions to ground The charging circuit has a failure for example the charging resistor is opened In this case the controller must be replaced There is a failure on the power modules which interfere with the capacitor charging The controller must be replaced Notice that this test is not carried out if the capacitor are already charged when you switch on the controller 12 VMN LOW VMN HIGH The test is carried out during initial diagnosis and in stand by when the phase voltages has to be about half the voltage on the power capacitors with MC closed each phase voltage is about half of the battery voltage An alarm condition is detected if a phase voltage is too close to ground VMN LOW or to battery voltage VMN HIGH The MC is opened and the controller is stopped if this alarm arises Possible causes A problem with the motor connections or the motor power circuit check if the 3 phases are correctly connected check if there s a dispersion of the
80. t 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 AFAZPOCB ACE5 INVERTER User Manual Page 13 72 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 account thermal and voltage drop problems EP 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 through the cable 4 2 4 l 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 co
81. tery before reparation maintenance Do not hesitate to contact Zapi technicians for help 10 1 Analysis of alarms for Traction controller Page 60 72 1 WATCH DOG The test is made in both running operation and in stand by It is a self diagnosing test within the electronic board If an alarm should occur the controller must be replaced 2 EEPROM KO Fault in the area of memory in which the adjustment parameters are stored this alarm inhibits machine operation If the defect persists when the key is switched OFF and ON again the controller must be replaced If the EEPROM KO alarm disappears remember that the parameters stored previously have been cancelled and replaced by the default values 3 LOGIC FAILURE 1 This alarm signals that an undervoltage overvoltage protection operation has occurred This alarms stops the controller operation and opens the MC Two possible reasons A Areal undervoltage overvoltage situation happened The alarm should disappear by simply switching off and on again the key The cause of the undervoltage overvoltage event has to be found on the application For example a very strong regenerative braking has increased too much the AFAZPOCB ACE5 INVERTER User Manual 4 5 6 7 8 9 battery voltage B Fault in the hardware section of the logic board which manages the hardware protection The controller must be replaced The activation of this alarm is regulated by inte
82. the inverter s configuration are made using the Digital Console The Console is connected to the B Molex Spox connector of the inverter 8 2 Additional programming tools Other tools are available to access the internal parameters and the other settings They are PC console it uses the same serial connection as the standard handset PC CAN console similar to the previous software but it requires a CAN connection Both of them are PC software which have to be installed in a computer Then in order to use them the computer must be connected to the Zapi inverter via serial line or CAN They access the internal settings in the same way as the handset does the names of the parameters alarm codes and all the other internal informations are the same as if an handset is being used In general the PC based tools provide larger flexibility than the standard Zapi handset especially if you have to review and modify many parameter settings EP If interested in one of these solutions please contact Zapi for further information AFAZPOCB ACE5 INVERTER User Manual Page 31 72 e Description of Console 8 Connection CONSOLE CONNECTOR A SN Z N A SN NN l NA XA DISPLAY 1 PARAM _ MAX SPEED ACC SPEED II BRAKING SPEED MI En R BRAKE HIDRO SP ak MAX SP HIDRO TIME 3 SAVE SP RED COMPENS 4 RESTORE I MOT V POT z i T
83. tion happened The alarm should disappear by simply switching off and on again the key The cause of the undervoltage overvoltage event has to be found on the application For example a very strong regenerative braking has increased too much the battery voltage B Fault in the hardware section of the logic board which manages the hardware protection The controller must be replaced The activation of this alarm is regulated by internal voltage thresholds which depend on the nominal battery voltage The list of these thresholds is the following e 36V 48V undervoltage 15V overvoltage 65V e 80V undervoltage 30V overvoltage 115V e 96V undervoltage 34V overvoltage 125V e 120V undervoltage 40V overvoltage 152V 4 LOGIC FAILURE 2 Fault in the hardware section of the logic board which reads the feedback signals of the phase s voltages This alarms stops the controller operation and opens the MC The controller must be replaced 5 LOGIC FAILURE 3 Fault in the hardware section of the logic board which manages the hardware current protection This alarms stops the controller operation and opens the MC The controller must be replaced 6 INCORRECT START This alarm signals an incorrect starting sequence Possible causes A microswitch failure B error in sequence made by the operator C incorrect or defective wiring Check all external cables and devices controlling the starting sequence In case the failure persists
84. ts the lower level of the battery discharge table 9 ADJUSTMENT 01 It adjusts the upper level of the battery discharge table A Page 42 72 AFAZPOCB ACE5 INVERTER User Manual 10 LOAD HM FROM MDI For an explanation of this point see the MDI instrument handbook Flow chart showing how to make changes to OPTION Menu ACST2BF zP1 00 1 Opening Zapi Menu BOV 10004 00000 2 Press Top Left 8 Right Buttons to enter SET Menu NOM oe 3 The Display will show SET MODEL 4 Press ROLL UP or ROLL DOWN button until SET MODEL Menu appears CONFIG MENU SET OPTIONS 5 SET OPTIONS appears on the display 6 Press ENTER to go into the SET MODEL Menu een HOUR COUNTER 7 The display will shows the first OPTION NINE 8 Press ROLL UP or ROLL DOWN button until mon desired OPTION appears mon BATTERY CHECK OFF 9 Desired OPTION appears 10 Press SET UP or SET DOWN button in order to OO E modify the changes Dou BATTERY CHECK 11 New OPTION appears aki oo 12 Press OUT to exit the Menu 7 a ARE YOU SURE 13 Confirmation request appears V S CENTER MAL BUT 14 Press ENTER to accept the changes or press OUT if you do not accept the changes CONFIG MENU SET OPTIONS 15 SET OPTIONS Menu appears 16 Press OUT again Display now show the Opening Zapi Menu AFAZPOCB ACE5 INVERTER User Manual Page 43 72 Flow chart showing how to make changes to ADJUSTMENT Me
85. umber D 128 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 AFAZPOCB ACE5 INVERTER User Manual Page 9 72 4 INSTALLATION HINTS In the following paragraphs you will find some boxes of different colours They mean EP These are information useful for anyone is working on the installation or a deeper explanation of the content A These are Warning boxes they describe operations that can lead to a failure of the electronic device or can be dangerous or harmful for the operator items which are important to guarantee system performance and safety 4 1 Wires and fuses Before starting it is necessary to have the reguired 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 in the 50 70 mm range as a minimum The correct size depends on the average current of a typical operating cycle of the application For the optimum inverter performance the cables to the battery should run side by side and be as short as possible 4 1 2 Fuse for I O circuits Use a fuse for protection of the auxiliary circuits normally this fuse is in series with the k
86. w shows the Opening Zapi Menu AFAZPOCB ACE5 INVERTER User Manual ACS5ST2BF ZP1 00 BOV 1000A 00000 NOM ood CONFIG MENU SET MODEL Bod ood CONFIG MENU ADJUSTMENTS OMO El El El SET BATTERY TYPE 48V OO E ood SET BATTERY TYPE BOV ood OMO ARE YOU SURE YES ENTER NO 0UT Page 45 72 Page 46 72 Flow chart showing how to carry out ADJUSTMENT BATTERY operation by console AGST2BF ZP1 00 1 Opening Zapi Menu BOV 1000A 00000 2 Press Top Left amp Right Buttons to enter CONFIG NOM Menu poo CONFIG MENU 3 The Display will show SET MODEL DE MONN 4 Press ROLL UP button until ADJUSTMENTS mon Menu appears Dou CONFIG MENU 5 ADJUSTMENTS appears on the display ADJUSTMENTS 6 Press ENTER to go into the ADJUSTMENTS a Menu poo SET BATTERY TYPE 7 The display will show the first OPTION Em 8 Press ROLL UP or ROLL DOWN button until desired OPTION appears 9 ADJUST BATTERY appears NOCI E O DO DO ADJUSTMENT BATTERY 82 1V 10 Press SET UP or SET DOWN button in order to COM increase or decrease respectively Set the value a read by an external 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
87. y 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 has to be 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 For this purpose the compartment must be ventilated and the dissipating area has to be large The size of heat sink material and system should satisfy 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 of the current drawn and the duty cycle 4 2 2 Connection of power cables A The power cables length must

ACE5 INVERTER - Zapi Inc USA

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