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DUALACE2 NEW GENERATION
Zapi DUALACE2 NEW GENERATION User Manual
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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
User Manual
DUALACE2 NEW
GENERATION
EN
2
Table of Contents
Table of Contents
3
Introduction
8
About this Document
8
Scope of this Manual
8
Terms and Abbreviations
8
Manual Revision
8
Warnings and Notes
8
About the Controller
10
Safety
10
Oem's Responsibility
10
Technical Support
10
Specifications
11
General Features
11
Technical Specifications
11
Current Ratings
12
Voltage Ratings
13
Drawings
14
Mechanical Drawings
14
Standard Version - Base-Plate with Fuse
14
Standard Version - Longitudinal Heatsink with Fuse
14
Standard Version - Transversal Heatsink with Fuse
15
Premium Version - Base-Plate with Fuse
15
Premium Version - Longitudinal Heatsink with Fuse
16
Premium Version - Transversal Heatsink with Fuse
16
Connection Drawings
17
Standard Version - Dual AC Traction Configuration
17
Standard Version - CAN Controlled Dual AC Traction Configuration
18
Standard Version - CAN Controlled Combi AC Configuration (AC Traction + AC Pump)
19
Premium Version - Dual AC Traction Configuration
20
Premium Version - Combi AC Configuration (AC Traction + AC Pump)
21
Premium Version - Dual BL Traction with Hall Sensors
22
Premium Version - Dual BL Traction with Sin/Cos Sensors
23
Premium Version - Combi BL Configuration (BL Traction + BL Pump) with Hall Sensors
24
Premium Version - Combi BL Configuration (BL Traction + BL Pump) with Sin/Cos Sensors
25
Premium Version - CAN Controlled Dual AC Traction Configuration
26
Premium Version - CAN Controlled Combi AC Configuration (AC Traction + AC Pump)
27
Premium Version - CAN Controlled Dual BL Traction with Hall Sensors
28
Premium Version - CAN Controlled Dual BL Traction with Sin/Cos Sensors
29
O Interface Description
30
Power Connectors
30
Ampseal Connector
30
Standard Version
30
Premium Version
32
Dual AC Traction Configuration
32
Combi AC Configuration (Traction + Pump)
35
Dual BL Traction with Sin/Cos Sensor
36
Dual BL Traction with Hall Sensors
37
Internal Connector
38
External Devices
38
Key Input
38
Digital Inputs
39
Analog Inputs
40
Encoder Input
41
MC Output
43
EB Outputs
44
PWM Current-Controlled Output
45
High-Side Driver
47
Motor-Temperature Measurement
47
Sensor Supply
48
CAN Bus
48
Installation Hints
50
Material Overview
50
Connection Cables
50
Contactors
50
Fuses
51
Installation of the Hardware
51
Positioning and Cooling of the Controller
51
Dust and Liquid Ingress Prevention
52
Wirings: Power Cables
52
Wirings: CAN Bus Connections and Possible Interferences
52
Wirings: I/O Connections
55
Motor Feedback Sensor
56
Incremental Encoder Speed Signals
56
Six-Step (or UVW) Encoder Signals
56
Sinusoidal Motor Speed Sensor Input
57
Connection of Motor Temperature Sensor
58
Connection of Main Contactor and Key Switch
58
Insulation of the Truck Frame
59
Emc
59
Features
61
Operational Features
61
Dual Traction Motor
61
Pump Motor
61
Torque Mode
62
Speed Mode
62
Protection and Safety Features
62
Protection Features
62
Safety Features
63
Start-Up Hints
64
Check Prior to Initial Power up
64
Configuring Motor Controller for the Application
65
Main Parameters Set-Up
65
Set-Up Additional Procedure for AC Pump Inverter
66
Position Sensor Acquisition
66
Programming & Adjustements
68
Settings Overview
69
Settings Description
71
Parameter Change
71
Valve Output
74
Parameter Pump
75
Set Option
77
Adjustments
85
Special Adjustment
90
Hardware Setting
93
SLV HW Setting
95
Tester Function
96
Tester - Master Microcontroller
96
Tester - Supervisor Microcontroller
101
Other Functions
106
Program VACC Function
106
Program LIFT / LOWER Function
106
Program STEER Function
107
Potentiometers
108
Acceleration Time
109
Release Modulation
110
Acceleration Smoothness
111
Steering Curve
111
Throttle Profile
112
MC and EB Modulation
113
Battery-Charge Detection
114
EVP Setup
115
Torque Profile
116
Steering Table
117
Motor Thermal Protection
119
Overvoltage and Undervoltage Limitations
120
Diagnostic System
121
ALARMS Menu
121
Diagnoses
121
Alarms from Master ΜC
123
Troubleshooting of Alarms from Master ΜC
126
Alarms from Supervisor ΜC
148
Troubleshooting of Alarms from Supervisor ΜC
151
Recommended Spare Parts
152
Periodic Maintenance
153
Appendices
154
Appendix A: PC CAN Console User Guide
154
PC CAN Console Configuration
154
Parameter Download
155
How to Modify Parameters
156
Program Vacc
157
Lift & Lower Acquisition
158
Steering Acquisition
158
TESTER Functionality
159
Alarm Logbook
159
Appendix B: Zapi Smart Console User Guide
160
Operational Modes
160
The Keyboard
161
Home Screen
161
Connected
162
How to Modify Parameters
163
Program Vacc
164
Lift and Lower Acquisition
165
Steer Acquisition
166
Tester
166
Alarms
166
Download Parameter List into a USB Stick
167
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Zapi DUALACE2 NEW GENERATION Specifications
General
Brand
Zapi
Model
DUALACE2 NEW GENERATION
Category
Controller
Language
English
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