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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

User Manual

ACE0 2µC

COMBIAC0 2µC

Publication:

AF6ZP0CA

Edition:

March 1, 2018

EN

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Summary of Contents for ACE0 2mC

Page 1: ...RIAL 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 ACE0 2 C COMBIAC0 2 C Publication AF6Z...

Page 2: ...o 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 publicatio...

Page 3: ...3 3 2 1 AC Traction configuration 13 3 2 2 AC Pump configuration 14 3 2 3 AC CAN Open configuration 15 3 2 4 PMSM Traction configuration 16 3 2 5 PMSM Pump configuration 17 4 I O INTERFACE DESCRIPTION...

Page 4: ...res 46 7 START UP HINTS 47 7 1 Check prior to initial power up 47 7 2 Configuring motor controller for the application 47 7 3 Set up procedure for AC traction inverter 48 7 3 1 Sin cos sensor case 48...

Page 5: ...sole configuration 139 13 1 2 Parameter download 141 13 1 3 How to modify the parameters 142 13 1 4 Program Vacc 143 13 1 5 Lift Lower command acquiring 143 13 1 6 Steer acquiring 144 13 1 7 Tester Fu...

Page 6: ...ous product improvement all data in this document are subject to change or correction without prior notice 1 1 3 Warnings and notes In this manual special attention must be paid to information present...

Page 7: ...esistor of about 10 100 Ohm between B and B terminals of the inverter 1 2 2 OEM s Responsibility Zapi motor controllers are intended for controlling motors in electric vehicles These controllers are s...

Page 8: ...th low speed control and zero speed holding control Zapi patented sensorless and sense coil control Driver for a line contactor Low side and high side drivers for an electromechanical brake short circ...

Page 9: ...sink temperature is measured internally near the power MOSFETs see paragraph 6 6 4 Two minute ratings are referred to an inverter equipped with a base plate No additional external heat sink or fans a...

Page 10: ...30V 4 Conventionally the controller can be set to operate without alarm in the range from 80 to 120 of the nominal battery voltage With a different DC voltage than specified the controller raises an a...

Page 11: ...AF6ZP0CA COMBIAC0 ACE0 2uC User Manual Page 11 155 3 DRAWINGS 3 1 Mechanical drawings 3 1 1 Base plate version 0 5 X 45 R 1 1 2 A3 COMBIAC0 AMPSEAL FRAMELESS DIMENSIONS 1 1 AS 26 05 15 AF6ZP7AA...

Page 12: ...Page 12 155 AF6ZP0CA COMBIAC0 ACE0 2uC User Manual 3 1 2 Longitudinal heat sink version 0 5 X 45 R 1 1 2 A3 COMBIAC0 AMPSEAL FRAMELESS LONGITUDINAL HEAT SINK DIMENSIONS 1 1 AS 26 05 15 AF6ZP7BA...

Page 13: ...AF6ZP0CA COMBIAC0 ACE0 2uC User Manual Page 13 155 3 2 Connection drawings 3 2 1 AC Traction configuration...

Page 14: ...Page 14 155 AF6ZP0CA COMBIAC0 ACE0 2uC User Manual 3 2 2 AC Pump configuration...

Page 15: ...AF6ZP0CA COMBIAC0 ACE0 2uC User Manual Page 15 155 3 2 3 AC CAN Open configuration...

Page 16: ...Page 16 155 AF6ZP0CA COMBIAC0 ACE0 2uC User Manual 3 2 4 PMSM Traction configuration...

Page 17: ...AF6ZP0CA COMBIAC0 ACE0 2uC User Manual Page 17 155 3 2 5 PMSM Pump configuration...

Page 18: ...16 kHz Terminal P is protected by short circuit detection voltage and current measurements Freewheeling diodes to B are built in MOSFETs internal diodes 4 2 Ampseal connector Inverter is equipped with...

Page 19: ...ated when the external switch is closed By default if HARD SOFT option is ON see 8 2 2Errore L origine riferimento non stata trovata the H S function is activated when the switch is closed A7 Input DI...

Page 20: ...ted when it is connected to B The default function is as HORN input Closing the switch the horn is activated A20 Input DI6 Digital input DI6 The input is activated when it is connected to B The defaul...

Page 21: ...DI3 The input is activated when it is connected to B The default function is as FW request Closing this input truck moves forward A33 Output EV3 Driving output for the PWM voltage controlled electrova...

Page 22: ...s connected to it 10 A fuse is recommended and the current absorption of the KEY input input power below 15 W U The key switch connected to the KEY input must handle the short inrush current spike to...

Page 23: ...listed below Custom hardware may feature different impedance values Inverter voltage 24 V 36 48 V 80 V Input impedance 4 5 k 14 5 k 30 k 4 Digital inputs DI1 DI2 DI5 DI6 DI7 DI8 and DI9 are normally...

Page 24: ...n request it is also possible to have the configuration on the right side of next figure potentiometer at rest in the middle still in combination with a couple of travel demand switches Potentiometer...

Page 25: ...e configuration permits to transform A18 and A21 in an interface for a sense coil or for an absolute sin cos sensor PMSM for special applications that use brushless motor For more details about sensor...

Page 26: ...ev D 128 pulses rev Encoder resolution can be changed through the dedicated parameters See paragraph 8 2 5 4 4 6 MC output Main or line contactor is operated through an open drain PWM voltage controll...

Page 27: ...y means of a suppressing device Protected against reverse polarity of the battery Built in diagnostics Overcurrent Driver shorted Driver open Coil open Refer to chapter 10 more details about alarms 4...

Page 28: ...i e if the return path integrity cannot be guaranteed in all situations external free wheeling diodes must be applied over the inductive loads supplied by the open drain outputs Output features Up to...

Page 29: ...l free wheeling diode if this is not possible U Use of brushless fans or other loads with built in capacitor can give high inrush current at turn on which can give an open drain over current trip The...

Page 30: ...rrent modulation at high frequency see paragraph 8 2 4 Dithering is typically used when controlling proportional valves in order to create microscopic movements in the valve to prevent it from stickin...

Page 31: ...inductive loads are connected such that the path for the free wheeling diode is always intact or use an external free wheeling diode if this is not possible U Use of brushless fan or other loads with...

Page 32: ...by suppressor device A low pass filter attenuates the noise from the motor Connector position A22 4 4 11 Sensor supply Supply for external motor speed sensors Output voltage is configurable via hardwa...

Page 33: ...lable for communication with the controller featuring Physical Interface according to ISO 11898 2 Data rate can be 125 250 or 500 kbit s CAN driver is 5 V supplied and provides a rail to rail signal o...

Page 34: ...rter it is necessary to have the required material for a correct installation Wrong choice of additional parts could lead to failures misbehaviors or bad performance 5 1 1 Connection cables For the au...

Page 35: ...time For safe operation onto the setup it is recommended to disconnect the battery and to discharge the capacitors by means of a resistor of about 10 100 between terminals B and B of the inverter 5 2...

Page 36: ...image The best type of cables for CAN bus 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 shielded cables where...

Page 37: ...the preferable connection is the daisy chain U Correct Layout Note Module 1 power Module 2 power Module 3 power The chain starts from the B post of the controller that deals with the highest current...

Page 38: ...eeds more and more data signal and information must flow from a node to another CAN bus is the solution to different problems that arise from this complexity simple design readily available multi sour...

Page 39: ...nection of an encoder with zero position signal U VERY IMPORTANT It is necessary to specify in the commercial order the type of encoder used in terms of power supply and electronic output so that the...

Page 40: ...specify the type of sensor used in terms of power supply electronic output and number of pulses per revolution because the logic unit and the software must be set in the correct way by Zapi 5 2 6 Con...

Page 41: ...ey switch The connection of the battery line switches must be carried out following instructions from Zapi If a mechanical battery line switch is installed it is necessary that the key supply to the i...

Page 42: ...SFETs at high frequency which can generate RF energy However wires have the key role to propagate disturbs because they work as antennas so a good layout of the cables and their shielding can solve th...

Page 43: ...with ferrite beads and bypass capacitors 3 ELECTROSTATIC IMMUNITY Three ways can be followed to prevent damages from ESD PREVENTION when handling ESD sensitive electronic parts ensure the operator is...

Page 44: ...ain more torque with current control The inverter can drive an electromechanical brake Hydraulic steering function When ACE0 COMBIAC0 works as traction inverter The traction inverter sends a hydraulic...

Page 45: ...des a driving experience like a car To prevent excessive speed when the load torque is low for example when driving down hill a maximum vehicle speed can be set 6 5 Speed mode In this mode the control...

Page 46: ...is reduced to half of the maximum current programmed Protection against accidental start up A precise sequence of operations are necessary for the machine to start Operation cannot begin if these ope...

Page 47: ...ify that the proper motor controller for the application has been installed 2 Verify that the battery voltage matches the motor controller nominal DC supply voltage showed on the product identificatio...

Page 48: ...ATION and ACCEL DELAY Test the behavior in both directions Set the FREQUENCY CREEP starting from 0 3 Hz The machine should just move when the drive request is active Increase the level accordingly Set...

Page 49: ...witching the inverter off using the key switch When the procedure is correctly completed the main contactor opens and display shows ACQUIRE END Re cycle the key switch and verify that the motor can ru...

Page 50: ...o the type of motor thermal sensor adopted Set the acceleration delay ACCEL MODULATION and ACCEL DELAY parameters Test the behavior in both directions Set the FREQUENCY CREEP starting from 0 3 Hz The...

Page 51: ...parameters To access and adjust all inverter parameters it is necessary to use the Zapi console Since the ACE0 COMBIAC0 has no external serial connector three possibilities are available To use the Za...

Page 52: ...EED STEERING TYPE THROTTLE Y3 MAP DEBUG CANMESSAGE HYDRO PUMP SPEED 5TH PUMP SPEED M C FUNCTION BAT MIN ADJ CONTROLLER TYPE HYDRO COMPENS HYD PUMP SPEED EBRAKE ON APPL BAT MAX ADJ SAFETY LEVEL PUMP IM...

Page 53: ...es depending on customer requests 8 2 1 PARAMETER CHANGE PARAMETER CHANGE Parameter Allowable range Description ACC TORQUE DEL T TM P CO 0 1 s 10 s steps of 0 1 s This parameter defines the accelerati...

Page 54: ...to 0 Hz A special software feature manages the deceleration ramp depending on the starting speed see paragraph 9 5 SPEED LIMIT BRK T TM 0 1 s 25 5 s steps of 0 1 s This parameter defines the decelerat...

Page 55: ...e It represents a percentage of TOP MAX SPEED CTB STEER ALARM T TM 0 100 steps of 1 This parameter defines the maximum traction speed when an alarm from the EPS is read by the microcontroller if the a...

Page 56: ...NGAGE DELAY T TM P CO 0 s 12 75 s steps of 0 05 s This parameter defines the delay introduced between the traction request and the actual activation of the traction motor This takes into account the d...

Page 57: ...0 05 s It determines the deceleration ramp on EVP2 The parameter sets the time needed to decrease the current from the maximum possible value to zero HYDRO SETTINGS COMBIAC0 has the possibility to dri...

Page 58: ...maximum voltage PU DC COMPENSAT A 0 100 steps of 1 This parameter defines the voltage compensation applied to the motor when the proportional lifting function is active The amount of compensation is a...

Page 59: ...r counts when the three phase power bridge is active or the DC motor power bridge is active or one of the valve outputs is active HM CUSTOM 2 OPT T TM P CO 0 6 This parameter decides the configuration...

Page 60: ...s or disables the stop on ramp feature the truck is electrically held in place on a slope for a defined time ON The stop on ramp feature is performed for a time set in the AUXILIARY TIME parameter OFF...

Page 61: ...The quick inversion function is not managed BRAKE Upon a quick inversion request the motor is braked TIMED The quick inversion function is timed upon a QI request the controller drives the motor in th...

Page 62: ...ype Low to High High to Low Direction switches Enable switch En dead band 0 11 Same as MAIN POT TYPE see previous parameter 12 No H to L X X 13 15 For future uses 13 15 For future uses 13 15 For futur...

Page 63: ...This parameter defines the configuration of the NLC output A12 dedicated to the main or line contactor OFF Main contactor is not present Diagnoses are masked and MC is not driven ON Main contactor is...

Page 64: ...ng to the signal received via CAN bus ON E B is managed by the controller itself ignoring any activation deactivation signal received via CAN bus AUTO LINE CONT CO OFF ON This parameter enables or dis...

Page 65: ...JUSTMENTS list paragraph 8 2 3 EV3 A ABSENT DIGITAL This parameter defines the behavior of output EV3 A33 ABSENT Output A33 is not enabled DIGITAL Output A33 manages a PWM voltage controlled valve The...

Page 66: ...to create a custom table It is strongly recommended to consult paragraph 9 13 in order to properly understand how to fill the following parameters If the steering performance of the truck do not match...

Page 67: ...8 2 3 ADJUSTMENTS ADJUSTMENTS Parameter Allowable range Description SET BATTERY A 24 V 80 V This parameter must be set to the nominal battery voltage The available options are 24V 36V 48V 72V 80V ADJU...

Page 68: ...ragraph 9 8 THROTTLE X1 MAP T TM P 0 100 steps of 1 This parameter defines the accelerator input curve See paragraph 9 8 THROTTLE Y1 MAP T TM P 0 100 steps of 1 This parameter defines the accelerator...

Page 69: ...RO VOLT T TM 0 V 25 5 V steps of 0 1 V This parameter records the maximum steering control voltage when it is in the straight ahead position See paragraph 9 3 MAX ANGLE RIGHT T TM 0 90 steps of 1 This...

Page 70: ...eter defines the CHECK UP NEEDED warning NONE no CHECK UP NEEDED warning OPTION 1 CHECK UP NEEDED warning shown on the hand set and MDI after 300 hours OPTION 2 Like OPTION 1 plus speed reduction inte...

Page 71: ...s the minimum offset voltage at the sine analog input during the auto teaching procedure It can be compared with the A SENS OFFSET SR entry value A SENS MAX CE Only for BLE0 A Volt This parameter reco...

Page 72: ...cedure CURR SENS COMP A OFF ON This parameter enables or disables the linear compensation for the current sensors NOTE only Zapi technicians can change this value through a special procedure DIS CUR F...

Page 73: ...ter defines the electrical frequency at which the switching frequency is changed from PWM AT LOW FREQ to PWM AT HIGH FREQ DITHER AMPLITUDE A 0 13 This parameter defines the dither signal amplitude The...

Page 74: ...er defines the safety level of the controller i e the functionality of the supervisor microcontroller 0 Supervisor C does not check any signal 1 Supervisor C checks the inputs and the outputs 2 Superv...

Page 75: ...hutdown due to an undervoltage condition RESOLVER PULSE A Used for special resolvers Reserved Note only Zapi technicians can change this value 8 2 5 HARDWARE SETTING The HARDWARE SETTINGS parameters g...

Page 76: ...rsion ROTATION CW ENC A OPTION 1 OPTION 2 It defines how the signal sequence coming from the encoder channels is expected by controller OPTION 1 Channel A anticipates channel B OPTION 2 Channel B anti...

Page 77: ...n The TESTER function gives real time feedbacks about the state of the controller the motor and command devices It is possible to know the state active inactive on off of the digital I Os the voltage...

Page 78: ...the encoder and expressed in the same unit of FREQUENCY Hz SLIP VALUE A Hertz 0 01 Hz Motor slip i e difference between the current frequency and the motor speed in Hz CURRENT RMS A Ampere 1 A Root me...

Page 79: ...E is zero TEMPERATURE A Celsius degrees 1 C Temperature measured on the inverter base plate This temperature is used for the HIGH TEMPERATURE alarm MOTOR TEMPERAT A Celsius degrees 1 C Motor windings...

Page 80: ...n done through a descent proportional valve on A24 not for BLE0 DI7 A35 LFT E DC only for COMBIAC0 T TM OFF ON Status of the digital input 7 pin A35 dedicated to the lift function only for COMBIAC0 DI...

Page 81: ...7 pin A35 dedicated to the 3 rd pump speed for ACE0 COMBIAC0 configured as pump controller DI8 A17 SPD4 SW P OFF ON Status of the digital input 8 pin A17 dedicated to the 4 th pump speed for ACE0 COM...

Page 82: ...REQ CO 255 steps Breaking torque setpoint of the AC motor transmitted over CAN bus expressed as percentage of the maximum torque A15 POT 1 A Volt 0 01 V Voltage of the analog input 1 pin A15 A30 POT...

Page 83: ...s percentage A4 ELEC BRAKE A 1 Voltage applied over the electromechanical brake coil It corresponds to the duty cycle value of PWM applied expressed as percentage CTRAP HW A Units 1 Counter showing th...

Page 84: ...oder i e encoder with index or zero signal ROTOR POSITION Only for BLE0 A Degrees 0 1 Real time absolute orientation of the rotor expressed in degrees TRUCK SPEED T TM CO km h 0 1 km h Speed of the tr...

Page 85: ...of the digital input 1 pin A7 DI2 A6 A OFF ON Status of the digital input 2 pin A6 DI3 A32 A OFF ON Status of the digital input 3 pin A32 DI4 A31 A OFF ON Status of the digital input 4 pin A31 DI5 A1...

Page 86: ...1 pin A15 A30 POT 2 A Volt 0 01 V Status of the analog input 2 pin A30 D11 A18 POT 3 A Volt 0 01 V Status of the analog input 3 pin A18 when the associated hardware is configured as analog input D12...

Page 87: ...hown Before calibration Vmot percentage is mapped over the default 0 5 V range instead after the adjustment procedure it results mapped over the useful voltage ranges of the potentiometer for both dir...

Page 88: ...VOLT STEER LEFT VOLT STEER ZERO VOLT See paragraphs 13 1 6 or 13 2 8 for acquiring procedure 9 4 Acceleration time The ACCEL DELAY parameter allows to define the acceleration rate depending on the fi...

Page 89: ...ck trace in the graph Initial speed 110 Hz Final speed setpoint 10 Hz DECEL BRAKING 2 5 s The deceleration time results 2 5 s Case 2 red trace in the graph Initial speed 60 Hz Final speed setpoint 10...

Page 90: ...CA COMBIAC0 ACE0 2uC User Manual Braking delay 4 Note This example is valid for all the braking related parameters DECEL BRAKING INVER BRAKING RELEASE BRAKING TILLER BRAKING PEDAL BRAKING SPEED LIMIT...

Page 91: ...s up to 5 result in smoother accelerations Acceleration smoothness 4 Note This example is valid for ACC SMOOTH BRK SMOOTH INV SMOOTH 9 7 Steering curve Steering related parameters CURVE SPEED 1 CURVE...

Page 92: ...hen the truck is moving slowly For the definition of such response the following parameters are used THROTTLE 0 ZONE of MAX VACC THROTTLE X1 POINT of MAX VACC THROTTLE Y1 POINT of MAX SPEED THROTTLE X...

Page 93: ...aph better displays the throttle speed relationship Throttle profile 9 9 NMC NEB output For the NMC output or NEB output there is the possibility to set a pull in voltage and to define a retention vol...

Page 94: ...of 70 9 10 Battery charge detection During operating condition the battery charge detection makes use of two parameters that specify the full charge voltage 100 and the discharged battery voltage 10 B...

Page 95: ...er stage is driven Vbatt is evaluated as the average value over a window of time 2 Vbatt is compared with a threshold value which comes as function of the actual charge percentage by this comparison t...

Page 96: ...ON OFF Valve is dependent by the OPEN DELAY and CLOSE DELAY parameters see paragraph 8 2 1 OPEN DELAY determines the current increase rate on EVP and it sets the time needed to increase the current t...

Page 97: ...lowering request is applied the current will increase from zero to MAX EVP in the time frame correspondent to OPEN DELAY value In the same way when the lowering request is removed the set point curren...

Page 98: ...Page 98 155 AF6ZP0CA COMBIAC0 ACE0 2uC User Manual Torque curves...

Page 99: ...teering table NONE custom steering table according to the following parameters o WHEELBASE MM distance between the front axle and the rear axle of the truck o FIXED AXLE MM axle width of the axle wher...

Page 100: ...ormed for temperatures between MAX MOTOR TEMP and STOP MOTOR TEMP It acts scaling down the torque profile see paragraph 9 12 by a percentage from 100 to MOT T T CUTBACK When motor temperature reaches...

Page 101: ...it is possible to stack different types of alarms with the following information 1 the alarm code 2 the number of times each alarm has consecutively occurred 3 the hour meter value at the last occurr...

Page 102: ...ult In case of fault it produces flash codes displaying all the active faults in a repeating cycle Each code consists of two digits see chapter 10 shown through the following sequence 1 the LED blinks...

Page 103: ...10 3 Alarms from master C Error code Effect Condition Restart procedure MDI LED CODE CAN OPEN CODE ZAPI CODE WAITING FOR NODE MC is opened EB is applied Traction Pump stopped Start up stand by runnin...

Page 104: ...applied EVP stopped Start up stand by running Traction Pump request 10 50F3 183 STALL ROTOR Traction Pump stopped Start up stand by running Valves or Traction Pump request 11 FFD3 211 CONTROLLER MISM...

Page 105: ...227 PUMP VMN NOT OK MC is not closed EB is applied Traction Pump valves stopped Start up Valves or Traction Pump request 33 FFBE 190 HW FAULT EB MC is opened EB is applied Traction Pump stopped Start...

Page 106: ...request 58 3201 252 CAPACITOR CHARGE MC is not closed EB is applied Traction Pump valves stopped Start up Valves or Traction Pump request 60 3130 60 THERMIC SENS KO Maximum current is reduced accordin...

Page 107: ...ction request 84 3223 195 VACC OUT RANGE Traction Pump motor is stopped Start up Stand by Running Traction Pump request 85 FFE2 226 VDC OFF SHORTED MC is not closed EB is applied Traction Pump valves...

Page 108: ...in A2 comes from by choosing a dedicated hardware configuration The parameter POSITIVE E B has to be set in accordance with the hardware configuration see paragraph 8 2 5 because the software makes a...

Page 109: ...The two digital inputs dedicated to the bumper functionality are high at the same time The alarm can occur only if parameter BUMPER STOP ON and only if the controller is in CAN OPEN configuration see...

Page 110: ...ed to the driver and ask for assistance to a Zapi technician in order to verify that the maximum current that can be supplied by the hardware is not exceeded In case no failures problems have been fou...

Page 111: ...to drive the load The device itself or its driver circuit is damaged Troubleshooting This type of fault is not related to external components replace the logic board CONTACTOR OPEN MDI LED code 38 Ca...

Page 112: ...l down between NMC A12 and B The driver circuit is damaged replace the logic board DRV SHOR EV 02 MDI LED code 21 Cause AUX valve driver is shorted Troubleshooting Check if there is a short circuit or...

Page 113: ...ry to replace the controller If the alarm disappears the previously stored parameters will be replaced by the default parameters ENCODER D ERR XX MDI LED code 3 Cause This alarm occurs only when the c...

Page 114: ...leshooting This fault is not related to external components Replace the logic board EVP DRIV SHORT MDI LED code 9 Cause The EVP driver output A24 is shorted The microcontroller detects a mismatch betw...

Page 115: ...r assistance to Zapi in order to verify that the software diagnoses are in accordance with the type of coil employed If the problem is not solved it could be necessary to replace the controller FIELD...

Page 116: ...litates Zapi technicians debugging the problem Troubleshooting This type of fault is not related to external components Replace the logic board HW FAULT EV XX MDI LED code 16 Cause At start up the har...

Page 117: ...it INIT VMN LOW XX MDI LED code 30 Cause Before closing the LC the software checks the power bridge voltage without driving it The software expects the voltage to be in a steady state value If it is t...

Page 118: ...Fault can be caused by a key input signal characterized by pulses below the undervoltage threshold possibly due to external loads like DC DC converters starting up relays or contactors during switchin...

Page 119: ...OTOR TEMP if analog see paragraph 8 2 3 Troubleshooting Check the temperature read by the thermal sensor inside the motor through the MOTOR TEMPERATURE reading in the TESTER function Check the sensor...

Page 120: ...coils Check the wiring If the problem is not solved replace the logic board OVERLOAD MDI LED code 57 Cause The motor current has overcome the limit fixed by hardware Troubleshooting If the alarm condi...

Page 121: ...no failures problems have been found the problem is in the controller which has to be replaced POSITIVE LC OPEN MDI LED code 35 Cause The positive voltage of LC is different from expected Troubleshoo...

Page 122: ...the motors the problem is inside the controller C If the alarm occurs during motor running check Motor internal connections If motor windings cables have leakages towards truck frame That the LC powe...

Page 123: ...ck to zero Troubleshooting Check the motor connection that there is continuity If the motor connection is opened the current cannot flow so the test fails and the error code is displayed If everything...

Page 124: ...if the resistance of the sensor is what expected measuring its resistance Check the wiring If the problem is not solved replace the logic board SIN COS D ERR XX MDI LED code 3 Cause This alarm occurs...

Page 125: ...encoder condition Check the wiring Through the TESTER function check if the sign of FREQUENCY and ENCODER are the same and if they are different from zero during a traction request If the problem is...

Page 126: ...been set in the throttle profile Troubleshooting Set properly the throttle related parameters see paragraph 9 8 TILLER ERROR MDI LED code 64 Cause Input mismatch between the Hard Soft input A6 and the...

Page 127: ...maximum and minimum potentiometer values through the PROGRAM VACC function If the alarm is still present check the mechanical calibration and the functionality of the accelerator potentiometer If the...

Page 128: ...ase voltages are expected to be lower than half the battery voltage If one of them is higher than that value this alarm occurs Troubleshooting If the problem occurs at start up the LC does not close c...

Page 129: ...t due to the fact that the pump motor is not still and show the PUMP VMN NOT OK alarm Troubleshooting If the motor connected to P is still moving just wait for it to be still If not in 30 seconds the...

Page 130: ...DI LED code 41 Cause At start up the controller checks the battery voltage measured at the KEY input A10 and it verifies that it is within a range of 20 around the nominal value Troubleshooting Check...

Page 131: ...19 5114 19 INPUT MISMATCH MC is opened EB is applied Traction Pump stopped Start up standby running Key re cycle 58 FFD5 213 W SET TG EB XX Traction Pump motor is stopped Start up stand by running Ke...

Page 132: ...cian in order to verify that the firmware is correct EEPROM KO MDI LED code 13 Cause A HW or SW defect of the non volatile embedded memory storing the controller parameters This alarm does not inhibit...

Page 133: ...t condition is triggered even if the power bridge is not driven Troubleshooting The failure lies in the controller hardware Replace the controller NO CAN MSG XX MDI LED code 67 Cause CANbus communicat...

Page 134: ...th respect to the master C The hexadecimal value XX facilitates Zapi technicians debugging the problem Troubleshooting Check the matching of the parameters between master and supervisor Ask for assist...

Page 135: ...a wrong setpoint for TG or EB output Troubleshooting Check the matching of the parameters between master and supervisor Ask for the assistance of a Zapi technician If the problem is not solved replace...

Page 136: ...e problem EVs are coded with a hexadecimal number 02 EV1 A9 04 EV2 A11 08 EV3 A33 20 EV4 A34 80 EV5 A8 If more than one EV circuit is found to be faulty the code shown corresponds to the sum of the si...

Page 137: ...0CA COMBIAC0 ACE0 2uC User Manual Page 137 155 11 SPARE PARTS Part number Description C12532 AMPSEAL CONNECTOR 35 pins Female C29508 SW 180 24V Single Pole Contactor C29522 SW 180 48V Single Pole Cont...

Page 138: ...sonnel 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 An...

Page 139: ...pendix A PC CAN Console user guide Windows Pc CAN Console uses standard Zapi communication protocol to display inverter s information It provides all standard Zapi Console functions with the easier ha...

Page 140: ...K button Once you have defined the CAN interface you have to choose which CAN device you need to connect to then choose Connection Set Node menu or push the Set Node icon Once you have chosen the node...

Page 141: ...nce you are connected to the selected node you need to download the inverter s parameters choose Function Parameter menu or push the Parameter icon Then click on Receive button the parameters will be...

Page 142: ...rameter various kinds of information are available in particular Parameter value as it is saved within controller Value column Parameter value as it is shown by console or similar tools Scaled Value c...

Page 143: ...ch either forward or backward Press the pedal up to its maximum excursion Displayed values will vary accordingly to operator inputs 13 1 5 Lift Lower command acquiring Once you are connected to the in...

Page 144: ...13 1 6 Steer acquiring Once you are connected you need to receive the inverter s parameter choose Function Parameter menu or push the Parameter icon Choose Adjustment menu Select the value to acquire...

Page 145: ...oller For every alarm will be shown the the working hour at which it s occurred the motor temperature and the number of repetitions Four buttons are present Update user can update alarm logbook Clear...

Page 146: ...Console offers the same serial connection as the well known Console Ultra Main characteristics of this operational mode are Current loop serial communication Console is connected to a single controlle...

Page 147: ...nd ESC keys OK key is used either to confirm actions or to enter a submenu ESC is used either to cancel an action or to exit a menu F1 F2 F3 keys These buttons have a contextual use The display will s...

Page 148: ...is ongoing If serial connection fails a NO COMMUNICATION warning will be shown after some seconds press ESC key and look for what is preventing the connection 4 Please notice the red dot appearing on...

Page 149: ...u inside that there is the parameter that you want to change for example the PARAMETER CHANGE menu With UP and DOWN keys you can scroll the whole list once you have highlighted the parameter that you...

Page 150: ...rent programmed values When OK is pressed PROGRAM VACC procedure will start console will invite you To select the Enable switch if any Then select the direction switch either forward or backward Press...

Page 151: ...ect the control switch if any either lift or lower Move the control sensor lift lower potentiometer to the correct position according to what you are acquiring Displayed values will vary accordingly t...

Page 152: ...cedure to follow is the same described in paragraph 13 2 7 13 2 9 Tester Compared to standard console Ultra the TESTER menu has been modified deeply Now it shows four variables at once use UP DOWN key...

Page 153: ...it has the possibility to download all parameters inside a USB stick To use this function enter the menu SAVE PARAMETER USB in the MAIN MENU File format The complete list of parameters is saved as a c...

Page 154: ...it does not work while being in Esc returns to HOME SCREEN OK starts download When saving files the console creates a subdirectory whose name has eight digits First four digits are controller type Fif...

Page 155: ...ESC and display will return to MAIN MENU USB stick can be removed safely Connect the USB stick to a PC and enter the directory of point 1 There will be a subdirectory with the correct name and inside...

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