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Zapi COMBIACX, User Manual

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AFCZP0BC- COMBIACX & ACEX - User Manual 

The Battery Charge detection follows this algorithm: 
 
1)  Battery voltages is read when the Battery current is zero, that is when the output 

power stage is not driven. 

2)  Vbatt is the mean of the least samples measured by the microcontroller 

converter (the samples are took on key input). 

3)  Vbatt is compared with a threshold value (function of the actual charge 

percentage) in a table and with comparison is found a new charge percentage. 

4)  Thresholds value can be changed with parameters Bat. Max. Adj. and Bat. Min. 

Adj. 

5)  After key on battery charge can be only increased if the battery charge 

computed after key on is greater than the last value stored in Eeprom the 
battery charge value is updated otherwise the Battery charge is not updated. 

Summary of Contents for COMBIACX

Page 1: ...TRONIC 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 User Manual COMBIACX A...

Page 2: ...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 ther...

Page 3: ...ontactors 11 4 1 3 Fuses 12 4 2 Installation of the hardware 12 4 2 1 Positioning and cooling of the controller 12 4 2 2 Wirings power cables 12 4 2 3 Wirings CAN connections and possible interference...

Page 4: ...4 4 Zapi menu SPECIAL ADJUSTMENTS functions list 49 10 4 5 Main menu TESTER functions list 50 11 OTHER FUNCTIONS 54 11 1 Description of console SAVE function 54 11 2 Description of console RESTORE fu...

Page 5: ...s Pump controller for series wounded DC motors up to 5 kW only for COMBIACX Driver for Line Contactor coil Drivers for ON OFF electrovalves and for one proportional valve electro distributor Low side...

Page 6: ...heatsink temperature start of the thermal cutback 85 C 4 Note 1 The DC chopper specifications are related to COMBIACX only 2 2 Technical specifications COMBIACX Power ACEX Power Inverter for traction...

Page 7: ...AFCZP0BC COMBIACX ACEX User Manual Page 7 81 2 3 Block diagrams 2 3 1 Traction control 2 3 2 Pump control...

Page 8: ...istance lower than 0 1Ohm and a leakage current lower than 100 A When full load connected the voltage between the key switch contacts must be lower than 0 1V If the microswitch to be used has differen...

Page 9: ...s possible to use this input for an alternative function like a proportional braking It should be in a 3 wire configuration Potentiometer value should be in the 0 5 10 kOhm range Generally the load sh...

Page 10: ...can also operate without encoder this using a sensorless control This solution has to be discussed with Zapi technicians 4 Note 1 The encoder resolution and the motor poles pair the controller can han...

Page 11: ...es 0 5mm section at least For power connections to the motor and to the battery use cables having a minimum section of 15 mm For the optimum inverter performance the cables to the battery should be ru...

Page 12: ...re planarity 0 05 mm and rugosity 1 6 m Apply a light layer of thermo conductive grease between the two surfaces to permit better heat dissipation The heat generated by the power block must be dissipa...

Page 13: ...ntrol applications CAN operates at data rate of up to 1 Megabits per second It was invented by the German company Bosch to be used in the car industry to permit communication among the various electro...

Page 14: ...modules are very different in terms of power then 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 BATT post of...

Page 15: ...N is the solution to different problems that arise from this complexity simplified design readily available multi sourced components and tools lower costs less and smaller cables improved reliability...

Page 16: ...5V 12V positive of encoder power supply D5 GND negative of encoder power supply D1 A phase A of encoder D4 B phase B of encoder 2 Connection of encoder with open collector output 5V and 12V power supp...

Page 17: ...wer battery line see picture below if not the inverter may be damaged if the switch is opened during a regenerative braking An intrinsic protection is present inside the logic when the voltage on the...

Page 18: ...otection meeting IP65 Nevertheless it is suggested to carefully study controller installation and position With few simple shrewdness the degree of controller protection can be strongly increased Prot...

Page 19: ...g norms EN12895 for industrial truck EN50081 2 for other applications EMC stands for Electromagnetic Compatibility and it represents the studies and the tests on the electromagnetical energy generated...

Page 20: ...for EMC issues depending on level of emissions immunity required the type of controller materials and position of the wires and electronic components 4 EMISSIONS Three ways can be followed to reduce t...

Page 21: ...X modules The filter capacitors contained in the COMBIACX ACEX module would change the SCR chopper operation and subject to excessive workload If it is necessary to use two or more control units like...

Page 22: ...otor and battery due to high frequency commutations Modification of parameters through the programming console Internal hour meter with values that can be displayed on the console Memory of the last f...

Page 23: ...t The default function is the controller HORN input closing the switch the horn output is activated A5 DI7 Input of the switch DI7 The input is activated when it is connected to Batt The default funct...

Page 24: ...B2 PEV Connect the positive supply of all electrovalves EV1 EV2 EV3 LOWER EVP HORN OUT to this pin Take the positive supply immediately after main contactor B3 NEVP Output of the lower proportional e...

Page 25: ...encoder phase A D2 PENC Encoder Positive Supply Hardware has to be configured to output 12V or 5 V D3 PTHERM Traction motor thermal sensor input The internal pull up is a fixed 2mA Max 5V source curr...

Page 26: ...ESCRIPTION OF POWER CONNECTIONS View of the power bars B Negative of the battery B Positive of the battery P Output of the Pump Motor COMBIACX only U V W Connection bars of the three motor phases foll...

Page 27: ...AFCZP0BC COMBIACX ACEX User Manual Page 27 81 8 DRAWINGS 8 1 Mechanical drawing COMBIACX...

Page 28: ...Page 28 81 AFCZP0BC COMBIACX ACEX User Manual 8 2 Mechanical drawing ACEX...

Page 29: ...AFCZP0BC COMBIACX ACEX User Manual Page 29 81 8 3 Connection drawing COMBIACX...

Page 30: ...Page 30 81 AFCZP0BC COMBIACX ACEX User Manual 8 4 Connection drawing ACEX...

Page 31: ...through a key switch at the KEY input CNC 1 This is the input for the controller supply Step6 Connect the Main Contactor Coil to CNC 1 and CNB 6 The contactor must connect the battery positive to the...

Page 32: ...heck the correct installation of all wires Use the Console s TESTER function to assist Step4 Perform the accelerator signal acquisition procedure using the Console PROGRAM VACC Procedure is detailed o...

Page 33: ...Set the parameter MAX SPEED BACK Reverse Step13 Test the truck on the maximum ramp specification at full load Step14 Make the choice for the truck behaviour on a slope If the Stop on ramp option is O...

Page 34: ...as to be connected through a remote module like a Zapi tiller card of a Zapi display This module has to be connected to the same Canbus line of the inverter 4 Otherwise it is possible to connect a pc...

Page 35: ...AFCZP0BC COMBIACX ACEX User Manual Page 35 81 10 3Description of the console menu 10 3 1 COMBIACX ACEX Menu...

Page 36: ...isplay will show SET MODEL CONFIG MENU SET MODEL Press ROLL UP or ROLL DOWN button until SET OPTIONS menu appear The Display will show SET OPTIONS CONFIG MENU SET OPTIONS Press ENTER to go in the SET...

Page 37: ...ON The counter registers when the key switch is closed controller supplied 4 EVP TYPE Analog digital defines the type of the EVP electrovalve current controlled Analog the related output manages a pro...

Page 38: ...al on off sensor for the motor temperature monitoring is connected to CND 3 input 2 NONE No temperature sensor is connected 9 EPS It can be set NONE NO EPS is present on the truck CombiACX does not wa...

Page 39: ...RESENT the Electro mechanic Brake is driven after a traction request if all the related diagnosis pass If is set ABSENT the diagnosis are masked and E B is not closed after a traction request 18 PROPO...

Page 40: ...sed 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 THROTTL...

Page 41: ...AX LIFT This parameter stores the maximum voltage of lifting potentiometer output connected to CNC 9 The max value acquisition is done closing the Lift SW and bringing the potentiometer in its max out...

Page 42: ...ivation It is expressed in percentage of the voltage applied during the first second defined by the previous parameter 20 PWM EV2 This parameter stores the PWM value applied to the EV2 coil It is expr...

Page 43: ...RELEASE BRAKING LEVEL 5 8 When the desired Parameter appears it s possible to change the Level by pressing either SET UP or SET DOWN buttons 9 The Display will show the new level RELEASE BRAKING LEVE...

Page 44: ...ded to decelerate the traction motor from 100Hz to 0Hz 8 EPS STEER BRAK Seconds It controls the deceleration ramp when a steer cutback is applied The parameter sets the time needed to decelerate the t...

Page 45: ...imum current of the controller 18 ACCELERATION SMOOTH It gives a parabolic form to the acceleration ramp 19 INVERSION SMOOTH It gives a parabolic form to the acceleration ramp after a direction invers...

Page 46: ...tor don t work when the 2ND request is ON 32 DESCENT SPEED From 0 to 100 It limits the maximum speed of the descent function Percentage of the maximum voltage applied to the pump motor for the descent...

Page 47: ...also determines the current value when the EVP is programmed like an ON OFF valve 39 EVP OPEN DELAY Seconds It determines the acceleration ramp on EVP The parameter sets the time needed to increase th...

Page 48: ...1 to 5 resolution 0 1 STOP SMOOTH Hz From 3 to 20 Hz resolution of 1Hz BRK SMOOTH Num From 1 to 5 resolution 0 1 STOP BRAKE SMOOTH Hz From 3 to 20 Hz resolution of 1Hz AUXILIARY TIME Sec From 0 to 10...

Page 49: ...URE Set the temperature offset to have the correct value reading This is a fine calibration of the controller temperature sensor 5 ADJUSTMENT 03 Factory adjusted value This is the gain of the Current...

Page 50: ...wave width is null 3 VOLTAGE BOOSTER Percentage value It is the booster contribute to the voltage really supplied to the motor expressed in per cent of the actual battery voltage Note when DC_LINK CO...

Page 51: ...gital input CNC 6 for the Tiller input ON VB When it is closed to a battery key voltage the Tiller input is Active OFF GND When it is not connected to a battery key voltage or it is connected to GND t...

Page 52: ...5 ON VB When it is closed to a battery key voltage the voltage the LIFTING request is active OFF GND When it is not closed to a battery key voltage or connected to GND the voltage the LIFTING request...

Page 53: ...his parameter shows the setpoint of EVP valve 29 EV1 FEEDBACK ON OFF This parameter shows the feedback of EV1 valve 30 EV2 FEEDBACK VOLTAGE This parameter shows the feedback of EV2 valve 31 EV3 FEEDBA...

Page 54: ...the Digital Console Opening Zapi Display ADXT2B ZP1 00 24V 165A 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 S...

Page 55: ...ll data in the controller memory will be written over and replaced with data being restored Flow Chart showing how to use the RESTORE function of the Digital Console Opening Zapi Display ADXT2B ZP1 00...

Page 56: ...nts associated with the potentiometer especially relating to the minimum level The two graphs show the output voltage from a non calibrated potentiometer with respect to the mechanical zero of the con...

Page 57: ...r 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 V...

Page 58: ...om the accelerator potentiometer is lower than this percentage of the MAX VACC setting This adjustment define the width of a dead zone close to the neutral position THROTTLE X POINT THROTTLE Y POINT t...

Page 59: ...ltage Level 10 These two settings are the Bat Max Adj and the Bat Min Adj It is possible to adapt the Battery Charge Detection to your specific battery by changing the above two settings e g if the Ba...

Page 60: ...ter the samples are took on key input 3 Vbatt is compared with a threshold value function of the actual charge percentage in a table and with comparison is found a new charge percentage 4 Thresholds v...

Page 61: ...the hourmeter indicated in this memory refers to the first time the alarm occurred In this way comparing this hourmeter with the controller hourmeter it is possible to determine When this alarm occurr...

Page 62: ...42 Driver of EB coil is damaged not able to close Valve pump traction stopped Lc opened Eb applied stby traction Valve or pump or traction request Pos EB shorted MDI CAN 86 Output of built in Smart Dr...

Page 63: ...or traction request Evp coil open MDI CAN 50 The Evp1 coil is not connected between PAUX and EVP output and the parameter EVP TYPE in the set option menu is set Analog or Digital valve pump traction...

Page 64: ...if the alarm disappears it means the controller internal charging resistance is damaged C The charging circuit has a failure inside the controller D There is a problem in the controller power section...

Page 65: ...the LC on the software checks the power bridge it turns on alternating the Low side and High side Power Mosfets and expects the phases voltage to decrease down to BATT increase up to Batt If the phase...

Page 66: ...river of the electromechanical brake coil is shorted Troubleshooting A Check if there is a short or a low impedance pull down between NEB CNA 4 and BATT B The driver circuit is damaged in the controll...

Page 67: ...ine contactor contact battery power cable connection 14 LOGIC FAILURE 2 Cause Fault in the hardware section of the logic board which manages the phase s voltage feedback Troubleshooting This type of f...

Page 68: ...to replace the encoder D If the problem is still present after replacing the encoder the failure is in the controller 20 TILLER ERROR Cause Mismatch between the H S input and the tiller input Troubles...

Page 69: ...negative of the coil and BATT Otherwise the driver circuit is damaged and the controller must be replaced 25 PUMP VMN LOW Cause The pump motor output is lower than expected considering the pwm applie...

Page 70: ...t is suggested to check that the coil is correctly connected between B1 and B5 If no problem is found on the coil the problem is inside the controller 30 PEV NOT OK Cause The PEV connector B2 is not c...

Page 71: ...ller 33 PUMP VMN NOT OK Cause Before switching the LC on the software checks the output voltage on P connector and expects it to be at a steady state value if TRUCK TYPE options is set to LEVEL 1 If t...

Page 72: ...is reduced if CHECK OPTION 1 continuous Eeprom ko MDI CAN 71 Error is detected in eeprom or in eeprom management Controller works using Deafult parameters continuous Motor temperat MDI CAN 65 Tractio...

Page 73: ...unction valve Ev3 request Pump Vacc not OK MDI CAN 89 The pump accelerator value is higher than the minimum value recorded and the lift lower switches are open Pump stopped Continuous Pump request Sen...

Page 74: ...emand active at key on B Presence man sensor active at key on Check the wirings Check the micro switches It could be also an error sequence made by the operator A failure in the logic is possible too...

Page 75: ...have been replaced by the default parameters 8 MOTOR TEMPERATURE Cause This warning occurs when the temperature sensor is opened if digital or has overtaken the threshold of 150 C if analog Troublesh...

Page 76: ...iver is shorted Troubleshooting Check if there is a short or a low impedance between the negative of this coil and BATT This warning occurs also if the external load is not present and the parameter E...

Page 77: ...ontroller 22 CONT DRV EV2 Cause The EV2 valve driver is not able to drive the load cannot close Troubleshooting The device or its driving circuit is damaged replace the controller 23 CONT DRV EV3 Caus...

Page 78: ...n presence Check the wirings Check the micro switches It could also be an error sequence made by the operator A failurw logic is possible too When all of the above conditions were checked and nothing...

Page 79: ...s 30 seconds for the voltage to be at the steady state value and for the pump motor to be still After this time the software assumes that the problem is not due to the fact that the pump motor is not...

Page 80: ...10 pins Female C12403 Connector Minifit 14 pins Female Part number Description Version C16604 Protected 100A strip fuse ACEX 36 48V C16529 Protected 125A strip fuse ACEX 24V C16502 Protected 160A stri...

Page 81: ...nt 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 Any variations or special...

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