Datasheet
ACE2 NEW
Publication: AFLZP0BA_PRELIMINARY
Edition: Feb 27, 2018
DESCRIPTION
ACE2 NEW GENERATION is suitable for
controlling several type of motors (AC induction,
BLDC and PMAC) in the range from 4 kW to 12
kW of continuous power, adopted in battery-
powered trucks for material handling.
It is available in two main configurations:
- Standard version: with a 23-poles connector
- Premium version: with a 35-poles connector,
for enhanced I/O.
The high number of I/O accommodates a wide
range of vehicle controls and sensors. ACE2 NG
can also easily interface with a wide range of
external devices via CAN bus.
APPLICATIONS
ACE2 NEW GENERATION is designed to handle
the electric functions usually present in material-
handling machines.
Typical applications are: counterbalanced trucks
with load up to 8 tons, HLOP (VNA), GSE, tow
tractors and airport ground support vehicles,
aerial-access equipment (telescopic boom and
scissor lift).
Furthermore, it may also be suitable for other
applications not listed here.
Zapi S.p.A. | Via Parma, 59 | 42028 Poviglio (RE) | ITALY
Tel. +39 522 960050 | Info: zapi@zapispa.it | Sales: sales@zapispa.it
www.zapigroup.com
GENERATION
FEATURES
 Nominal voltage from 24 V to 80 V.
 Microcontroller for main functions, 576+ kByte
embedded flash memory.
 Microcontroller for safety functions, 320+ kByte
embedded flash memory.
 Up to 8 active-high digital inputs.
 Up to 3 active-low digital inputs.
 Up to 4 analog inputs (range 0 V ÷ 10 V) with 10-
bit resolution.
 1 input for analog motor thermal sensor.
 Possible speed sensor interfaces:
 1 incremental encoder (default).
 2 incremental encoders.
 1 sin/cos sensor.
 1 set of three Hall sensors.
 1 resolver.
 CAN bus interface allows communication with a
wide range of devices.
 Communication speed up to 500 kbit/s.
 Communication standard: CAN protocol.
 11-bit and 29-bit communication supported.
 Auxiliary supply output (+12V/+5V, up to 200mA).
 1 PWM current-controlled low-side output with
current feedback (up to 1.5 A continuous).
 Up to 4 PWM voltage-controlled low-side outputs.
 Up to 1 ON/OFF voltage-controlled low-side
output.
 Built-in freewheeling diodes.
 Dither injection configurable in amplitude and
frequency.
 Protection from overload, short circuit, open load
and ESD.
 Ambient temperature
 Operating: -40 °C ÷ +40 °C.
 Storage: -40 °C ÷ +85 °C.
 Sealed connector (23-pins or 35-pins Ampseal).
 Access to status and diagnostic information.
 ACE2 NEW GENERATION

MODEL CHART
Nominal Voltage 2-min current S2 60-min current
voltage range rating [Arms] rating [Arms]
550 275
36/48V 10 V ÷ 65 V
450 225

Incoming versions
Nominal Voltage 2-min current S2 60-min current
voltage range rating [Arms] rating [Arms]
550 275
500 250
24V 10 V ÷ 35 V 450 225
400 200
350 175
500 250
36/48V 10 V ÷ 65 V 400 200
350 175
400 200
350 175
72/80V 30 V ÷ 115 V
300 150
250 125

 Current ratings are based on an initial temperature of the power section of 40 °C and a maximum
one of 85 °C. No additional external heat sink is used for the 2-minute rating test.

 Inverter can continuously deliver the rated RMS current only if it is adequately cooled. When it is
equipped with its own finned heat sink, a proper dissipation is obtained by applying a 100 m /h
3

airflow. In case the inverter is provided with the base plate, it is customer’s duty to design an
adequate cooling system that can dissipate the heat produced by the inverter, keeping its
temperature below 85 °C.

REGULATIONS
UL certificate UL 583 compliant (AU3503).
Applicable requirements of EN 1175-1:2010,
Functional safety
Compliant to upcoming revision of EN1175.
EMC Applicable requirements of EN 12895.
IP code IP65.

Zapi S.p.A. | Via Parma, 59 | 42028 Poviglio (RE) | ITALY

Tel. +39 522 960050 | Info: zapi@zapispa.it | Sales: sales@zapispa.it
www.zapigroup.com
 ACE2 NEW GENERATION
TECHNICAL DATA
Version STANDARD PREMIUM
Ampseal connector 23-pins Ampseal 35-pins Ampseal
Active high 3 8
Digital inputs
Active low 2 3
Analog inputs 2 4
PWM voltage-controlled outputs 2 4
ON/OFF output - 1
PWM current-controlled output 1
Auxiliary supply output (+12/+5V) 2 (max 200 mA)
CAN bus interface 1
Input for motor thermal sensor 1
Encoder interface 1 1 (2 on demand)
Sin-cos / 3-Hall / resolver interface - 1 on demand
Main μC 576+ kB Flash, 48 kB SRAM, 64kB emulated EEPROM
Memory
Supervisor μC 320+ kB Flash, 32 kB SRAM, 64 kB emulated EEPROM

 Speed sensor interfaces different from single incremental encoder reduce the
number of digital/analog inputs available.

DIMENSIONS
The base plate version is shown.
Transversal and longitudinal heat
sink versions are available too.

Zapi S.p.A. | Via Parma, 59 | 42028 Poviglio (RE) | ITALY

Tel. +39 522 960050 | Info: zapi@zapispa.it | Sales: sales@zapispa.it
www.zapigroup.com
 ACE2 NEW GENERATION
TYPICAL WIRING DIAGRAM – STANDARD VERSION

Zapi S.p.A. | Via Parma, 59 | 42028 Poviglio (RE) | ITALY

Tel. +39 522 960050 | Info: zapi@zapispa.it | Sales: sales@zapispa.it
www.zapigroup.com
 ACE2 NEW GENERATION
TYPICAL WIRING DIAGRAM – PREMIUM VERSION

Zapi S.p.A. | Via Parma, 59 | 42028 Poviglio (RE) | ITALY

Tel. +39 522 960050 | Info: zapi@zapispa.it | Sales: sales@zapispa.it
www.zapigroup.com