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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: [email protected] – web: www.zapispa.it

FREE VERSION

User Manual

AC-0 SSL

SENSORED

Summary of Contents for AC-0 SSL

Page 1: ...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 FREE VERSION User Manual AC 0 SSL SENSORED ...

Page 2: ...ake 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 is a registered trademark property of Zapi S p A NOTES LEGEND 4 The symbol aboard is used inside thi...

Page 3: ... 2 6 Main contactor and key connection 15 4 2 7 Insulation of truck frame 15 4 3 Protection and safety features 15 4 3 1 Protection features 15 4 3 2 Safety Features 16 4 3 3 Passive emergency cell 16 4 4 EMC 17 5 OPERATIONAL FEATURES 20 5 1 Diagnosis 20 6 DESCRIPTION OF THE CONNECTORS 22 6 1 Connectors of the logic Traction configuration 22 6 1 1 Standard version with Encoder 22 6 1 2 MDI PRC ver...

Page 4: ...ction 75 10 4 Shortform table of the aux output 1 setting traction version 77 10 5 Description of the throttle regulation 78 10 6 Description of the battery charge detection setting 79 11 AC 0 ALARMS LIST TRACTION CONFIGURATION 80 11 1 Main menu ALARMS list 80 11 1 1 One Blink Alarms 80 11 1 2 Two Blinks Alarms 81 11 1 3 Three Blinks Alarms 82 11 1 4 Four Blinks Alarms 83 11 1 5 Five Blinks Alarms...

Page 5: ... RECOMMENDED SPARE PARTS 99 14 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED 100 APPROVAL SIGNS COMPANY FUNCTION INITIALS SIGN GRAPHIC AND LAYOUT CP PROJECT MANAGER MI TECHNICAL ELECTRONIC MANAGER VISA PP SALES MANAGER VISA PN Publication N AE0ZP0EC Edition September 2006 ...

Page 6: ...er for the 24 V AC 0 SSL with Encoder is FZ2008 The 36 V has a different part number is FZ3006 AC 0 has also a big brother controller called AC 1 both are available in the Sensored version The only differences between AC 0 and AC 1 are the maximum current 150 A vs 250 A and the dimensions All the Zapi AC controllers have the CAN Bus communication peripheral and a Serial Link embedded the SW for th...

Page 7: ...nterface Digital control using a microcontroller Encoder Interface Voltage 24 36 V Maximum current 24 V 36 V 150 A RMS for 2 Maximum current 48 V 120 A RMS for 2 Booster all version 170 A RMS for 10 seconds Operating frequency 8 kHz with center aligned PWM External temperature range 30 C 40 C Maximum inverter temperature at full power 78 C 2 2 Block diagram Figure 2 1 ...

Page 8: ...h CNB 12 with about 12 Vdc CPOT CNB 10 signal ranges is from 0 to 10 V Potentiometer value should be in the 0 5 10 kΩ range generally the load should be in the 1 5 mA to 30 mA range Faults can occur if it is outside this range The standard connection for the potentiometer is the one in the Left side of Figure 3 1 potentiometer on one end at rest in combination with a couple of Travel demand switch...

Page 9: ...nus battery voltage e g CNA 8 3 5 Speed feedback The motor control is based upon the motor speed feedback The speed transducer is an incremental encoder with two phases shifted at 90 The encoder can be of different types power supply 5 V or 12 V electric output open collector NPN or PNP push pull The wished resolution must be specified when ordering the controller The suggested resolution is from ...

Page 10: ...tery should be run side by side and be as short as possible 4 1 2 Contactors Usually a main contactor is adopted to connect and cut off the battery to the controller Depending on the setting of a parameter see AUX VOLTAGE 1 option in Set options submenu the output which drives the main contactor coil is on off the coil is driven with the full battery voltage the output which drives the main contac...

Page 11: ...o be possible the compartment must be ventilated and the heat sink materials ample The heat sink material and system should be sized on the performance requirement of the machine Abnormal ambient air temperatures should be considered In situations where either ventilation is poor or heat exchange is difficult forced air ventilation should be used The thermal energy dissipated by the power block mo...

Page 12: ...of the system to disturbances a good choice would be to use a cable with a shield connected to the frame of the truck Sometimes it is sufficient a simple double wire cable or a duplex cable not shielded In a system like an industrial truck where power cables carry hundreds of Ampere there are voltage drops due to the impedance of the cables and that could cause errors on the data transmitted throu...

Page 13: ... 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 U Correct Layout Note Module 1 power Module 2 power 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 dr...

Page 14: ...r cavities U A cable connected to the wrong pin can lead to short circuits and failure so before turning on the truck for the first time verify with a multimeter the continuity between the starting point and the end of a signal wire For information about the mating connector pin assignment see the paragraph description of the connectors 4 2 5 Connection of the encoder 1 AC 0 card is fit for differ...

Page 15: ...tection it is allowed that the Main Contactor or an emergency switch breaks the Battery positive in every moment regardless of the state of the key without this protection if the Main Contactor breaks when a regenerative braking is in progress the rail capacitor voltage increases and the overvoltage could damage the Power Mosfets Figure 4 1 4 2 7 Insulation of truck frame U As stated by EN 1175 Sa...

Page 16: ...ied out correctly Requests for drive must be made after closing the key switch 4 3 2 Safety Features U ZAPI controllers are designed according to the prEN954 1 specifications for safety related parts of control system and to UNI EN1175 1 norm The safety of the machine is strongly related to installation length layout and screening of electrical connections have to be carefully designed ZAPI is alw...

Page 17: ...t is possible it keeps the motor moving against of the state of the commands To avoid this risk the Passive Emergency cell provides a further step of safety that is a redundancy in processing the motion request Tiller or Seat Switch In our controller the truck will be stopped releasing the tiller disregarding if the main Elaboration Unit uC is right working or not 4 4 EMC U EMC and ESD performance...

Page 18: ...e 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 dete...

Page 19: ... parts ensure the operator is grounded test grounding devices on a daily basis for correct functioning this precaution is particularly important during controller handling in the storing and installation phase B ISOLATION use anti static containers when transferring ESD sensitive material C GROUNDING when a complete isolation cannot be achieved a good grounding can divert the discharge current tro...

Page 20: ... 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 10 4 and STOP ON RAMP option in Set options submenu Hydraulic steering function 1 traction inverter the traction inverter sends a hydraulic steering function r...

Page 21: ...ion that checks contactor driver current sensors can bus interface 4 Continuous diagnosis that checks temperature of the inverter motor temperature Diagnosis is provided in two ways The digital console can be used which gives a detailed information about the failure the failure code is also sent on the Can Bus ...

Page 22: ...100 AE0ZP0EC AC 0 SSL SENSORED User Manual 6 DESCRIPTION OF THE CONNECTORS AC 0 INVERTER FV FU FW B B Figure 6 1 6 1 Connectors of the logic Traction configuration 6 1 1 Standard version with Encoder Figure 6 2 ...

Page 23: ...ve low switch opened A16 12V This output provides a 12 V signal for thr MDI PRC if present 100 mA maximum current A17 CAN HIGH High level CAN BUS voltage I O A18 CPOTB Brake potentiometer wiper A19 ENC A Encoder Channel A A20 ENC B Encoder Channel B CNB connector B1 KEY SW Connected to the power supply through a microswitch KEY with a 6 3 10 A fuse in series this could be mounted on the AC 0 cover...

Page 24: ...ower supply C7 FLASH Must be connected to C8 for the Flash memory programming if used C8 FLASH Must be connected to C7 for the Flash memory programming if used 6 1 2 MDI PRC version with Encoder Figure 6 3 CNA connector A1 NMC Negative of main contactor coil A2 PMC Positive of main contactor coil A3 NEB Output for driving the electromechanical brake coil drives the load to Batt Maximum current 3 A...

Page 25: ...oltage level B3 TILLER SW Tiller request input Must be connected to the tiller microswitch active high B4 H S SW Hard Soft request input Must be connected to the Hard Soft microswitch active high B5 BACKWARD SW Backward direction request input Must be connected to the backward direction microswitch active high B6 FORWARD SW Forward direction request input Must be connected to the forward direction...

Page 26: ...e of the third auxiliary output A7 CAN LOW Low level CAN BUS voltage I O A8 BATT Batt A9 ENC Encoder Positive Supply 5 or 12 Vdc A10 ENC Encoder Negative Supply GND to minus battery A11 HM B This output provides a Batt for general purpose applications 3 A maximum current A12 BATT Batt A13 MOT TH Motor thermal sensor input The internal pull up is a fixed 2 mA Max 5 V source current A14 SPEED 3 Inpu...

Page 27: ...ble input it is active high B7 HYDRO STEER Input for hydraulic steering request Active high B8 SR Speed reduction input Active low switch opened B9 SPEED 4 Input for fourth speed request it is active high B10 CPOT Lift potentiometer wiper B11 NPOT Negative of accelerator unit tested for wire disconnection diagnosis B12 PPOT Potentiometer positive 10 V output keep load 1 kΩ CNC connector C1 PCLRXD ...

Page 28: ...6 3 Description of power connections View of the power bars B INVERTER AC 0 FW FV B FU Figure 6 5 B Negative of the battery B Positive of the battery FU FV FW Connection bars of the three motor phases follow this sequence and the indication on the motor ...

Page 29: ...AE0ZP0EC AC 0 SSL SENSORED User Manual Page 29 100 7 DRAWINGS 7 1 Mechanical drawing B Voltage Reference ZAPI PRODUCTION DATA B FW FU FV INVERTER AC 0 Figure 7 1 ...

Page 30: ...Page 30 100 AE0ZP0EC AC 0 SSL SENSORED User Manual 7 2 Connection drawing Traction configuration 7 2 1 Standard version with Encoder B B AC 0 INVERTER FW FV FU Figure 7 2 ...

Page 31: ...AE0ZP0EC AC 0 SSL SENSORED User Manual Page 31 100 7 2 2 MDI PRC Version with Encoder AC 0 FV INVERTER FW B B FU Figure 7 3 ...

Page 32: ...Page 32 100 AE0ZP0EC AC 0 SSL SENSORED User Manual 7 3 Connection drawing Pump configuration B B AC 0 INVERTER FW FV FU Figure 7 4 ...

Page 33: ... battery voltage through a key switch at the KEY input CNB 1 this is the input for the logic supply Step6 Connect the Main Contactor Coil to CNA 1 and CNA 2 The contactor must make and take the plus battery power cable to the BATT power terminal of the AC 0 Step7 Connect the motor and the minus battery to the corresponding power terminals of the AC 0 Step8 Connect the Electromechanical Brake betwe...

Page 34: ...arting from 0 6 Hz The machine should just move when the accelerator microswitch is closed Increase the Level accordingly Step8 Set the Speed Reductions as required Use the parameters of the cutback speed family in the PARAMETER CHANGE menu to specify the reduced maximum truck speed as a percentage of the MAX SPEED FWD and MAX SPEED REV see 9 5 1 9 10 11 12 Step9 RELEASE BRAKING Operate the machin...

Page 35: ...e is supplied on the CNB 2 connection Step4 Connect the encoder in the motor shaft between CNA 9 ENC CNA 10 ENC CNA 19 ENC A CNA 20 ENC B The ENC voltage may be 13 V or 5 V depending on a jumper inside the controller see also 4 2 5 Step5 Connect the plus battery voltage through a key switch at the KEY input CNB 1 this is the input for the logic supply Step6 Connect the Main Contactor Coil to CNA 1...

Page 36: ...both directions Step7 Set the FREQUENCY CREEP level starting from 0 6 Hz The pump should just move when the accelerator microswitch is closed Increase the Level accordingly Step8 Set the Speed Reductions as required Use the parameters of the cutback speed family in the PARAMETER CHANGE menu to specify the reduced maximum pump speed as a percentage of the 1ST 2ND 3RD and 4TH SPEED FINE see 9 5 2 St...

Page 37: ...f Parameters and changes to the inverter s configuration are made using the Digital Console The Console is connected to the CNC connector of the inverter 9 2 Description of console hand set connection Figure 9 1 Digital consoles used to communicate with AC inverter controllers must be fitted with EPROM CK ULTRA minimum Release Number 3 02 ...

Page 38: ...unctions Numbers inside the triangles correspond to the same number on the hand set keyboard buttons shown in the Figure 9 1 The orientation of the triangle indicates the way to the next function 9 3 Description of standard console menu 9 3 1 Traction configuration Standard version Figure 9 2 ...

Page 39: ...AE0ZP0EC AC 0 SSL SENSORED User Manual Page 39 100 MDI PRC Version Figure 9 3 ...

Page 40: ...Page 40 100 AE0ZP0EC AC 0 SSL SENSORED User Manual 9 3 2 Pump configuration Figure 9 4 ...

Page 41: ...d It is connected to a key voltage when the operator is present There are two levels HANDLE CNB 3 is managed as tiller input no delay when released SEAT CNB 3 is managed as seat input with a delay when released 2 SET INPUT 1 This setting handles the analog input CNA 13 It can be used one of three Level 0 CNA 13 is managed as input for an analog motor thermal sensor KTY84 130 Level 1 CNA 13 is mana...

Page 42: ... when CNB 7 is opened 6 HOUR COUNTER This option specifies the hour counter mode It can be set one of two RUNNING The counter registers travel time only KEY ON The counter registers when the key switch is closed 7 BATTERY CHECK This option specifies the handling of the low battery charge detection It can be set one of three Level 0 Nothing happens the battery charge level is ignored Level 1 A BATT...

Page 43: ...ent this output can sink is up to 3 Adc 11 PEDAL BRAKING The analog input CNA 18 has one of two function Pedal Braking Input Command input for lifting lowering proportional valves in MDI PRC version To turn from the first to the second function is just enough to set PEDAL BRAKING to NONE This option handles the analog input CNA 18 when used as pedal braking input ANALOG With this setting is possib...

Page 44: ...tage 14 TRUCK TYPE MDI PRC version only This option specifies the hydraulics handling when the MDI PRC is present 1 Both the Main Lifting Lowering pair CNB 9 and CNB 8 and the Aux Lifting Lowering pair CNA 14 and CNA 15 are used to activate two Lifting Lowering distinct circuits double forks truck Main Lifting enables both the pump contactor on CNA 4 and a valve to re direct the oil in the main hy...

Page 45: ...o enable the On Off descent valve connected on CNA 6 The CNA 18 potentiometer modulates the current in the lowering proportional valve pin 8 MDI PRC when the Lowering request is active To do a Lowering function the current in the proportional valve progressively increases meanwhile the CNA 18 potentiometer increases to accelerate the Lowering 15 MDI PRC This option specifies PRESENT The MDI PRC is...

Page 46: ...s the actual value of the CNA 18 potentiometer The MAX LIFT setting must be Entered after the Lifting control Lever is pushed against the maximum limiting position 5 MIN LOWER MDI PRC version only By entering this setting the SW records the actual value of the potentiometer on CNA 18 The MIN LOWER setting must be Entered with the CNA 18 potentiometer in a position is a little bit ahead the Main Lo...

Page 47: ... position but with two different slope see also Figure 10 2 14 ADJUSTMENT 01 It adjusts the upper level of the battery charge table Level 0 to 9 See paragraph 10 6 15 ADJUSTMENT 02 It adjusts the lower level of the battery charge table Level 0 to 9 See paragraph 10 6 16 LOAD HM FROM MDI When set On the HourMeter of the Controller is transferred and recorded on the HourMeter of the Standard MDI con...

Page 48: ...eat input with a delay when released 2 MOTION OPTIONS This option handles the hydraulic steering function activation It can be set one of four EXCLUSIVE HYDRO the hydraulic steering function is activated only if the pressure switch is active the pressure switch can be wired on the pump inverter input CNB 7 but the request can also arrive from traction via can bus OPTION 2 the hydraulic steering fu...

Page 49: ...g function when the key is switched ON only if the AUX OUTPUT 1 option is programmed as HYDRO CONTACTOR or as EXCLUSIVE HYDRO 7 AUX OUTPUT 1 Not used 8 AUX VOLTAGE 1 This option specifies the percentage of the key voltage to be applied to the loads on CNA 1 main contactor coil and CNA 3 aux output The voltage modulation is got with a PWM at 1 kHz frequency After an initial delay of about 1 sec in ...

Page 50: ...Y POINT This parameter together with the THROTTLE X POINT changes the characteristic of the accelerator input curve see also paragraph 10 5 when the accelerator is depressed to X point per cent the corresponding truck speed is Y point per cent of the Maximum truck speed The relationship between the accelerator position and the truck speed is linear between the THROTTLE 0 ZONE and the X point and a...

Page 51: ...ours OPTION 2 Equal to OPTION 1 but Speed reduction after 340 hours OPTION 3 Equal to OPTION 2 but the truck definitively stops after 380 hours 17 OPTION 05 Not used 18 OPTION 04 Not used 19 OPTION 03 Not used 20 OPTION 02 Not used 21 OPTION 01 Not used ...

Page 52: ...The Display will show SET OPTIONS CONFIG MENU SET OPTIONS Press ENTER to go in the SET OPTIONS MENU The Display will show the first OPTION HOURCOUNTER RUNNING Press SET UP or SET DOWN button in order to modify the OPTION The Display will show the new option HOURCOUNTER KEYON Press OUT to exit the menu The Display will ask ARE YOU SURE ARE YOU SURE YES ENTER NO OUT Press ENTER for YES or OUT for No...

Page 53: ... ADJUSTMENTS MENU appears ADJUSTMENTS appears on the display CONFIG MENU ADJUSTMENTS Press ENTER to go into the ADJUSTMENTS MENU The display will show SET BATTERY TYPE BATTERY TYPE 24V Press ROLL UP or ROLL DOWN button until the desired parameter is reached The desired parameter is appears THROTTLE 0 ZONE 3 Press SET UP or SET DOWN button to modify the adjustment THROTTLE 0 ZONE 7 Press OUT Press ...

Page 54: ...eased and the brake pedal switch is pressed to its maximum At Level 9 the truck brakes abruptly 5 SPEED LIMIT BRK Level 0 to 9 It controls the deceleration ramp when the accelerator has turned down but not completely released At Level 9 the truck decelerate abruptly 6 BRAKE CUTBACK Level 0 to 9 It controls the deceleration ramp when a speed reduction input becomes active and the motor slows down A...

Page 55: ... submenu 16 INCHING TIME Standard version only because the inching switches are used for the Lifting and Lowering switches in the MDI PRC version Level 0 to 9 It determines the during time when the Inching function is active 17 AUXILIARY TIME Time units value seconds For the encoder version it determines the time duration the truck is kept on the ramp if the STOP ON RAMP option is ON 18 MIN VALVE ...

Page 56: ...ng it is possible to take care the voltage on the EVD1 and EVD2 never overcomes the nominal voltage of the valves 23 VALVE3 VOLTAGE MDI PRC version only A percentage from 0 to 100 This parameter determines the voltage applied to the EVD1 this is connected on the pin 6 of the MDI PRC in percentage of the above VALVES VOLTAGE setting The voltage applied to this electrovalve is a PWM technique genera...

Page 57: ...eters can be set PROGRAMMED LEVEL PARAMETER UNIT 0 1 2 3 4 5 6 7 8 9 ACCELER DELAY Sec 2 05 3 00 3 05 4 00 4 05 5 00 5 05 6 00 6 05 7 00 RELEASE BRAKING Sec 5 05 5 00 4 05 4 00 3 05 3 00 2 05 2 00 1 05 1 00 INVERS BRAKING Sec 5 05 5 00 4 05 4 00 3 05 3 00 2 05 2 00 1 05 1 00 PEDAL BRAKING Sec 5 05 5 00 4 05 4 00 3 05 3 00 2 05 2 00 1 05 1 00 SPEED LIMIT BRK Sec 8 09 8 03 7 07 7 01 6 06 6 00 5 05 4...

Page 58: ...d by the software the real ramp could change as a function of motor control parameter setting and obviously as a function of the load 9 5 2 Pump The following parameters can be modified 1 ACCELER DELAY Level 0 to 9 It determines the acceleration ramp At Level 9 the truck takes long time to accelerate 2 DECELER DELAY Level 0 to 9 It controls the deceleration ramp when the travel request is released...

Page 59: ...st half of its nominal value see the table 12 AUXILIARY TIME Not used 13 MIN VALVE 1 Not used 14 MIN VALVE 2 Not used 15 MAX VALVE 1 Not used 16 MAX VALVE 2 Not used 17 VALVES VOLTAGE Not used 18 VALVE3 VOLTAGE Not used 19 VALVE4 VOLTAGE Not used 20 V1 OPENING RAMP Not used 21 V2 OPENING RAMP Not used 22 V1 CLOSING RAMP Not used 23 V2 CLOSING RAMP Not used 24 HYDRO DELAY Time units value seconds I...

Page 60: ...Not used VALVE4 VOLTAGE Not used V1 OPENING RAMP Not used V2 OPENING RAMP Not used V1 CLOSING RAMP Not used V2 CLOSING RAMP Not used HYDRO DELAY Sec 0 00 1 28 1 42 3 20 3 84 5 12 7 04 9 60 10 8 16 0 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 a...

Page 61: ...eter ACC DELAY LEVEL 5 Press either ROLL UP and ROLL DOWN to display the next parameter The names of the Parameters appear on the Display RELEASE BRAKING LEVEL 5 When desired Parameter appear it s possible to change the Level by pressing either SET UP or SET DOWN buttons The Display will show the new level RELEASE BRAKING LEVEL 2 When you are satisfied with the result of the changes you have made ...

Page 62: ...Page 62 100 AE0ZP0EC AC 0 SSL SENSORED User Manual 9 5 3 Zapi menu HARDWARE SETTINGS functions list Confidential documentation ...

Page 63: ...action and pump configuration have the same functions list 1 ADJUSTMENT 01 Factory adjusted value This is the Gain of the first Current Sensing Amplifier NOTE keep your hand off this setting 2 ADJUSTMENT 02 Factory adjusted value This is the Gain of the second Current Sensing Amplifier NOTE keep your hand off this setting 3 SET TEMPERATURE Factory adjusted C value Reserved use NOTE keep your hand ...

Page 64: ...battery voltage Note when DC_LINK COMPENSATION is set ON the VOLTAGE BOOSTER reading will not match perfectly the booster setting because this latest one is calculated respect to the nominal battery voltage VOLTAGE BOOSTER is expressed respect to the actual battery voltage 4 FREQUENCY Hz value with two decimal digit This is the frequency of the sine waves the inverter is supplying 5 ENCODER Hz val...

Page 65: ...0 V meanwhile the corresponding LIFTING CONTROL reading is in the range 0 0 to 5 0 Vdc 14 LIFTING SWITCH ON OFF This is the level of the CNB 9 digital input Lifting request ON VB When CNB 9 is closed to a battery key voltage the Lifting request is Active OFF GND When CNB 9 is not connected to a battery key voltage or it is connected to GND the Lifting request is not active 15 DESCENT SWITCH ON OFF...

Page 66: ...n disabled 21 H S CUTBACK ON OFF This is the level of the CNB 4 digital input Hard Soft request With the H S service is possible to turn the truck moving at reduced speed only by acting the H S switch and the accelerator without to let down the tiller ON VB When CNB 4 is closed to a battery key voltage the H S request is Active OFF GND When CNB 4 is not connected to a battery key voltage or it is ...

Page 67: ...SENT this is the Speed Reduction 3 request ON GND When CNA 15 is not closed to a battery key voltage or connected to GND the SR 3 request is active OFF VB When CNA 15 is closed to a battery key voltage the SR 3 request is not active This input CNA 15 has the alternative function of Inching Backward request when the SET INPUT 3 is set to OPTION 1 Then the Inching Backward request turns active meanw...

Page 68: ...e value of the line current in the motor 8 BATTERY CURRENT Ampere value This is a coarse calculation not a measurement of the battery current 9 BATTERY CHARGE Percentage value It supplies the residual charge of the battery as a percentage of the full charge level 10 TEMPERATURE C value This is the temperature of the inverter base plate This temperature is used for the HIGH TEMPERATURE alarm detect...

Page 69: ... This is the level of the CNB 7 digital input hydro speed request ON VB When CNB 7 is closed to a battery key voltage the hydro speed request is active OFF GND When CNB 7 is not connected to a battery key voltage or it is connected to GND the hydro speed request is not active 18 HANDLE SEAT SW ON OFF This is the level of the CNB 3 digital input Tiller or seat swit ON VB When CNB 3 is closed to a b...

Page 70: ...Page 70 100 AE0ZP0EC AC 0 SSL SENSORED User Manual is active OFF VB When CNB 7 is closed to a battery key voltage the hydraulic steering function is not active ...

Page 71: ... the SAVE function of the Digital Console Opening Zapi Display AC0 ZAPI V0 0 24V 150A 00000 Press ENTER to go into the General menu The Display will show MAIN MENU PARAMETER CHANGE Press ROLL UP or ROLL DOWN button until SAVE PARAM appears on the display The Display will show MAIN MENU SAVE PARAMETERS Press ENTER to go into the SAVE function If this facility has been used before the type of choppe...

Page 72: ...Page 72 100 AE0ZP0EC AC 0 SSL SENSORED User Manual Press OUT to return to the Opening Zapi Display NOTE in reality the SAVE and RESTORE function requires the Windows PC Console ...

Page 73: ...the RESTORE function of the Digital Console Opening Zapi Display AC0 ZAPI V0 0 24V 150A 00000 Press ENTER to go into the General menu The Display will show MAIN MENU PARAMETER CHANGE Press ROLL UP or ROLL DOWN button until SAVE PARAM appears on the display The Display will show MAIN MENU RESTORE PARAM Press ENTER to go into the RESTORE PARAM function The Display shows the type of Model stored with...

Page 74: ...ZP0EC AC 0 SSL SENSORED User Manual When finished the Console shows MAIN MENU RESTORE PARAM Press OUT to return to the Opening Zapi Display NOTE in reality the SAVE and RESTORE function requires the Windows PC Console ...

Page 75: ...hanical 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 Figure 10 1 This function looks for and remembers the mi...

Page 76: ... output Both directions can be shown VACC SETTING 4 8 4 8 Press ENTER to clear these values Display will show 0 0 Select Forward Direction close any interlock switches that may be in the system MIN VACC MAX 0 0 0 0 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 directio...

Page 77: ...very slowly when the time set by auxiliary time parameter is elapsed the brake is applied and the 3 phase bridge is opened Do not use this combination if the negative brake is not installed HYDRO CONT ON Drives the coil of a hydraulic steering contactor The truck is electrically hold on a slope when the time set by auxiliary time parameter is elapsed the truck comes down very slowly till the flat ...

Page 78: ...or potentiometer is lower than this percentage of the MAX VACC setting This adjustment defines the width of a dead zone close to the rest position see Figure 10 2 below THROTTLE X POINT THROTTLE Y POINT the speed of the truck grows up with a fixed slope linear relationship from the THROTTLE 0 ZONE up to THROTTLE X POINT This slope is defined by the matching between the X point percentage of the MA...

Page 79: ...harge Voltage Level 10 These two settings are the ADJUSTMENT 01 and the ADJUSTMENT 02 see Adjustments submenu It is possible to adapt the Battery Charge Detection to your specific battery by changing the above two settings e g if the Battery Discharged Detection occurs when the battery is not totally discharged it is necessary to reduce the ADJUSTMENT 02 setting as indicated in the Figure 10 3 bel...

Page 80: ... WATCH DOG MDI PRC Code 8 Cause It occurs when the embedded WATCH DOG protection is not able either to cut off the power stage when not triggered or it is not able to activate the power stage when triggered Remedy Verify the motor is connected and the continuity of the three motor phases If the alarm occurs permanently it is necessary to replace the controller 2 EEPROM KO MDI PRC Code 13 Cause It ...

Page 81: ...n the CHECK UP DONE option to level ON see Adjustments submenu after the maintenance is executed 11 1 2 Two Blinks Alarms 1 INCORRECT START MDI PRC Code 79 Cause This is just a warning for an incorrect starting sequence Remedy The possible reasons for this alarm are use the readings in the TESTER to facilitate the troubleshooting a A travel demand active at key on b The tiller switch active at key...

Page 82: ...dy The possible reasons for this alarm are use the readings in the TESTER to facilitate the troubleshooting When MDI PRC is absent at least one between LIFTING SWITCH CNB 9 or DESCENT SWITCH CNB 8 active at key on When TRUCK TYPE is Level 1 at least one between LIFTING SWITCH CNB 9 DESCENT SWITCH CNB 8 DIGITAL INPUT 1 CNA 14 or DIGITAL INPUT 2 CNA 15 active at key on When TRUCK TYPE is Level 2 at ...

Page 83: ...he Batt terminal of the controller is lower voltage than the Battery voltage this alarm occurs Main Contactor has lost the contact although it is closed Remedy If the problem occurs before the Main Contactor closes probably a Power failure e g a Bottom side Power Mosfet short circuited or a Top side Power Mosfet broken or a Logic Failure occurred in the controller If the problem occurs when the op...

Page 84: ... the potentiometer voltage is higher than 200 mV over the MAX LOWER setting see Adjustments submenu If the MIN LIFT setting is higher than the MAX LIFT setting If the MIN LOWER setting is higher than the MAX LOWER setting When the TRUCK TYPE is set 3 the alarms occurs in the following conditions If the Main Lowering request is disactive and the potentiometer voltage is higher than the MIN LOWER se...

Page 85: ...lem is due to a short circuit of one of the coils connected to these outputs After the overload has removed the alarm exits automatically by releasing and then enabling a travel demand Remedy Check the coils of the main contactor CNA 1 of the electromechanical brake CNA 3 of the pump contactor CNA 4 of the Aux valve CNA 6 2 CONTACTOR DRIVER MDI PRC Code 75 Cause This alarm occurs when the voltage ...

Page 86: ... Brakes the truck probably the Driver of the Electromechanical Brake is short circuited and this alarm occurs b When the feedforward PWM is higher than 70 of the battery voltage the Actual voltage on the Electromechanical Brake is expected high If it is lower than 14 V it means the Electromechanical Brake always gets the truck Braked probably the Driver of the Electromechanical Brake is opened and...

Page 87: ...nt decreases proportionally with the temperature increases from 78 C up to 100 C At 100 C the current is limited to 0 Amps Remedy Improve the air cooling of the controller 2 MOTOR TEMPERAT MDI PRC Code 65 Cause This is just a warning with no effect on the truck performance It occurs when the temperature of the motor winding overtakes the MOTOR OVERTEMP setting Remedy Check the thermal sensor insid...

Page 88: ...his alarm occurs 2 WAITING FOR NODE MDI PRC Code Null Cause The controller expects to receive a message from a remote module via CAN Bus When this message is not received after a time out this alarm occurs Remedy Check the communication via CAN between the controller and the other modules 3 CURRENT SENS KO MDI PRC Code 94 Cause This alarm occurs when the procedure for the maximum current set up is...

Page 89: ... EEPROM KO 16 AUX OUTPUT KO 17 LOGIC FAILURE 3 18 LOGIC FAILURE 2 19 LOGIC FAILURE 1 30 VMN LOW 31 VMN HIGH 37 CONTACTOR CLOSED 38 CONTACTOR OPEN 49 I 0 EVER 53 STBY I HIGH 55 PROGRAM LIFT LEVER 60 CAPACITOR CHARGE 61 HIGH TEMPERATURE 65 MOTOR TEMPERAT 67 CAN BUS KO 70 ENCODER ERROR 71 HANDBRAKE 73 THERMIC SENS KO 74 DRIVER SHORTED 75 CONTACTOR DRIVER 76 COIL SHORTED 78 VACC NOT OK 79 INCORRECT ST...

Page 90: ... least one On Off driver on pin 4 and 6 is shorted 75 MDI DRV2 OPEN At least one On Off driver on pin 4 and 6 is opened 89 MDI PEV NOT OK The Positive Supply for the Valves is missing 90 MDI NEVP1 NOT OK At least one Proportional Valve driver on pin 8 and 9 is shorted Example 02A79 is an INCORRECT START alarm on the AC 0 traction controller ...

Page 91: ...ATCH DOG MDI PRC Code 8 Cause It occurs when the embedded WATCH DOG protection is not able either to cut off the power stage when not triggered or it is not able to activate the power stage when triggered Remedy Verify the motor is connected and the continuity of the three motor phases If the alarm occurs permanently it is necessary to replace the controller 2 EEPROM KO MDI PRC Code 13 Cause It oc...

Page 92: ...NE option to level ON see Adjustments submenu after the maintenance is executed 12 1 2 Two Blinks Alarms 1 INCORRECT START MDI PRC Code 79 Cause This is just a warning for an incorrect starting sequence Remedy The possible reasons for this alarm are use the readings in the TESTER to facilitate the troubleshooting a Error in sequence made by the operator b Incorrect wiring c The seat switch active ...

Page 93: ...occurs Main Contactor has lost the contact although it is closed Remedy If the problem occurs before the Main Contactor closes probably a Power failure e g a Bottom side Power Mosfet short circuited or a Top side Power Mosfet broken or a Logic Failure occurred in the controller If the problem occurs when the operator turns the truck moving the problem is the Battery positive is not connected to th...

Page 94: ...m 2 STBY I HIGH MDI PRC Code 53 Cause This diagnosis is executed only when the main contactor is opened and asked to be closed e g at key on or when the main contactor is opened and a new motion request turns active Then the outputs of the Current amplifiers must be in a narrow window close to 2 5 Vdc from 2 26 V to 2 74 V Otherwise this STBY I HIGH alarm occurs Remedy If the alarm occurs permanen...

Page 95: ... the Main Contactor is higher than expected this means that the Main Contactor Coil has a high voltage although it is not supplied Remedy Probably it is necessary to replace the controller because the driver of the Main Contactor is short circuited 6 AUX OUTPUT KO MDI PRC Code 16 Cause This alarm occurs when the feedforward PWM generated by the controller to supply the Electromechanical Brake and ...

Page 96: ...Alarms 1 CAN BUS KO MDI PRC Code 67 Cause It occurs if the controller does not receive any message from the CAN Bus line Remedy First of all check the wiring If it is OK try to disconnect one to one the module connected to the CAN Bus and check if this alarm disappears When you are quite sure the problem is in the present module it is necessary to replace the controller 12 1 9 No Blink Alarms 1 WR...

Page 97: ...Remedy The maximum current set up is factory adjusted and so this alarm never should happen when the controller is on the field So ask for the assistance of a Zapi technicians when this alarm occurs 12 1 10 Thirty Two Blinks Alarms 1 BATTERY LOW MDI PRC Code Local Cause It occurs when the battery charge is calculated being less than 10 of the full charge and the BATTERY CHECK setting is other than...

Page 98: ...Device Code 05 is the following 1 WRONG CONFIG 8 WATCH DOG 13 EEPROM KO 16 AUX OUTPUT KO 17 LOGIC FAILURE 3 18 LOGIC FAILURE 2 19 LOGIC FAILURE 1 30 VMN LOW 31 VMN HIGH 37 CONTACTOR CLOSED 38 CONTACTOR OPEN 49 I 0 EVER 53 STBY I HIGH 60 CAPACITOR CHARGE 61 HIGH TEMPERATURE 65 MOTOR TEMPERAT 67 CAN BUS KO 70 ENCODER ERROR 73 THERMIC SENS KO 74 DRIVER SHORTED 75 CONTACTOR DRIVER 76 COIL SHORTED 78 V...

Page 99: ... Page 99 100 13 RECOMMENDED SPARE PARTS Part number Description C29508 SW 180 24V Single Pole Contactor C12407 Molex Minifit Connector 12 pins Female C12408 Molex Minifit Connector 20 pins Female C12777 Female Molex Minifit pin harness side ...

Page 100: ...ables 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 replac...

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