Zapi DUALACE2 NEW GENERATION

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AFNZPxxx– DUALACE2 NEW GENERATION – User Manual Page 7/169

APPROVAL SIGNS

COMPANY FUNCTION

INITIALS

SIGN

PROJECT MANAGER

TECHNICAL ELECTRONIC

MANAGER VISA

SALES MANAGER VISA

REVISIONS TABLE

1.0

30/01/2020

First Release

REVISION

DATA

MOTIVATION

FUNCTION

SIGN

APPROVAL

WRITING

Main Page

Table of Contents3
Introduction8
About this Document8
Scope of this Manual8
Terms and Abbreviations8
Manual Revision8
Warnings and Notes8
About the Controller10
Safety10
Oem's Responsibility10
Technical Support10
Specifications11
General Features11
Technical Specifications11
Current Ratings12
Voltage Ratings13
Drawings14
Mechanical Drawings14
Standard Version - Base-Plate with Fuse14
Standard Version - Longitudinal Heatsink with Fuse14
Standard Version - Transversal Heatsink with Fuse15
Premium Version - Base-Plate with Fuse15
Premium Version - Longitudinal Heatsink with Fuse16
Premium Version - Transversal Heatsink with Fuse16
Connection Drawings17
Standard Version - Dual AC Traction Configuration17
Standard Version - CAN Controlled Dual AC Traction Configuration18
Standard Version - CAN Controlled Combi AC Configuration (AC Traction + AC Pump)19
Premium Version - Dual AC Traction Configuration20
Premium Version - Combi AC Configuration (AC Traction + AC Pump)21
Premium Version - Dual BL Traction with Hall Sensors22
Premium Version - Dual BL Traction with Sin/Cos Sensors23
Premium Version - Combi BL Configuration (BL Traction + BL Pump) with Hall Sensors24
Premium Version - Combi BL Configuration (BL Traction + BL Pump) with Sin/Cos Sensors25
Premium Version - CAN Controlled Dual AC Traction Configuration26
Premium Version - CAN Controlled Combi AC Configuration (AC Traction + AC Pump)27
Premium Version - CAN Controlled Dual BL Traction with Hall Sensors28
Premium Version - CAN Controlled Dual BL Traction with Sin/Cos Sensors29
O Interface Description30
Power Connectors30
Ampseal Connector30
Standard Version30
Premium Version32
Dual AC Traction Configuration32
Combi AC Configuration (Traction + Pump)35
Dual BL Traction with Sin/Cos Sensor36
Dual BL Traction with Hall Sensors37
Internal Connector38
External Devices38
Key Input38
Digital Inputs39
Analog Inputs40
Encoder Input41
MC Output43
EB Outputs44
PWM Current-Controlled Output45
High-Side Driver47
Motor-Temperature Measurement47
Sensor Supply48
CAN Bus48
Installation Hints50
Material Overview50
Connection Cables50
Contactors50
Fuses51
Installation of the Hardware51
Positioning and Cooling of the Controller51
Dust and Liquid Ingress Prevention52
Wirings: Power Cables52
Wirings: CAN Bus Connections and Possible Interferences52
Wirings: I/O Connections55
Motor Feedback Sensor56
Incremental Encoder Speed Signals56
Six-Step (or UVW) Encoder Signals56
Sinusoidal Motor Speed Sensor Input57
Connection of Motor Temperature Sensor58
Connection of Main Contactor and Key Switch58
Insulation of the Truck Frame59
Emc59
Features61
Operational Features61
Dual Traction Motor61
Pump Motor61
Torque Mode62
Speed Mode62
Protection and Safety Features62
Protection Features62
Safety Features63
Start-Up Hints64
Check Prior to Initial Power up64
Configuring Motor Controller for the Application65
Main Parameters Set-Up65
Set-Up Additional Procedure for AC Pump Inverter66
Position Sensor Acquisition66
Programming & Adjustements68
Settings Overview69
Settings Description71
Parameter Change71
Valve Output74
Parameter Pump75
Set Option77
Adjustments85
Special Adjustment90
Hardware Setting93
SLV HW Setting95
Tester Function96
Tester - Master Microcontroller96
Tester - Supervisor Microcontroller101
Other Functions106
Program VACC Function106
Program LIFT / LOWER Function106
Program STEER Function107
Potentiometers108
Acceleration Time109
Release Modulation110
Acceleration Smoothness111
Steering Curve111
Throttle Profile112
MC and EB Modulation113
Battery-Charge Detection114
EVP Setup115
Torque Profile116
Steering Table117
Motor Thermal Protection119
Overvoltage and Undervoltage Limitations120
Diagnostic System121
ALARMS Menu121
Diagnoses121
Alarms from Master ΜC123
Troubleshooting of Alarms from Master ΜC126
Alarms from Supervisor ΜC148
Troubleshooting of Alarms from Supervisor ΜC151
Recommended Spare Parts152
Periodic Maintenance153
Appendices154
Appendix A: PC CAN Console User Guide154
PC CAN Console Configuration154
Parameter Download155
How to Modify Parameters156
Program Vacc157
Lift & Lower Acquisition158
Steering Acquisition158
TESTER Functionality159
Alarm Logbook159
Appendix B: Zapi Smart Console User Guide160
Operational Modes160
The Keyboard161
Home Screen161
Connected162
How to Modify Parameters163
Program Vacc164
Lift and Lower Acquisition165
Steer Acquisition166
Tester166
Alarms166
Download Parameter List into a USB Stick167

Zapi DUALACE2 NEW GENERATION - Page 7

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