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AF6ZP0AL - COMBIAC0 & ACE0 - User Manual

Error code

Description

Effect

Machine status

when the test is

done

Restart

procedure

Coil shor. Ev. - MDI
CAN 76

Shortcircuit on On/off valves coil

On/off valves stopped start-up, stby,

during valve
function

valve on/off request

EV1/5 driver shorted
- 74

EV1 or EV2 on/off valve drivers
shorted (always ON)

On/off valves stopped start-up, stby

valve on/off request

EV2 driver shorted -
MDI CAN 74

EV2 on/off valve driver shorted
(always ON)

On/off valves stopped start-up, stby

valve on/off request

EV3 driver shorted -
MDI CAN 74

EV3 on/off valve driver shorted
(always ON)

On/off valves stopped start-up, stby

valve on/off request

EV4 driver shorted -
MDI CAN 74

EV4 on/off valve driver shorted
(always ON)

On/off valves stopped start-up, stby

valve on/off request

Evp1 not ok - MDI
CAN 48

Evp driver open (not able to close,
so not able to drive the valve)

Evp stopped

during Evp
function

valve evp request

Evp2 not ok - MDI
CAN 47

Evp2 driver open (not able to close,
so not able to drive the valve)

Evp stopped

during Evp
function

valve evp request

Pump I NO zero -
MDI CAN 56

Pump chopper current sensor
feedback is out of permitted stby
range

Pump motor stopped

start-up, stby

pump request

Pump I=0 ever -
MDI CAN 52

Pump current feedback is always
0A even when pump motor is
running

Pump motor stopped

pump function

pump request

lift+lower - 49

lift+lower request

Pump motor stopped

continuous

hydraulic request

Cont. Drv. Ev1 - MDI
CAN 75

Driver of Ev1 is open, not able to
close

Ev1 stopped

during Ev1
function

valve Ev1 request

Cont. Drv. Ev2 - MDI
CAN 75

Driver of Ev2 is open, not able to
close

Ev2 stopped

during Ev2
function

valve Ev2 request

Cont. Drv. Ev3 - MDI
CAN 75

Driver of Ev3 is open, not able to
close

Ev3 stopped

during Ev3
function

valve Ev3 request

Cont. Drv. Ev4 - MDI
CAN 75

Driver of Ev4 is open, not able to
close

Ev4 stopped

during Ev4
function

valve Ev4 request

Cont. Drv. Ev5 - MDI
CAN 75

Driver of Ev5 is open, not able to
close

Ev5 stopped

during Ev5
function

valve Ev5 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

Sens. Mot. Temp.
KO - MDI CAN 67

The motor temperature sensor is
damaged

Performance highly
reduced

Continuous

Key-on recycle

BACKING INPUT -

MDI CAN 78

An inching request is performed
and the tiller input is active, or FW
or REV input is active

Traction is stopped

start-up, stand-
by, traction

traction request

Содержание COMBI AC0

Страница 1: ...CTRONIC 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 COMBIAC0 ACE0 ...

Страница 2: ...e 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 this ...

Страница 3: ...2 Contactors 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 13 4 2 3 Wirings CAN connections and possible interferences 13 4 2 4 Wirings I O connections 15 4 2 5 Connection of the encoder 16 4 2 6 Main contactor and key connection 17 4 2 7 Insulation of truck frame 17 4 3 Protection and safety features 18 4 3 1 Pr...

Страница 4: ...ons list 47 11 OTHER FUNCTIONS 51 11 1 Description of console SAVE function 51 11 2 Description of console RESTORE function 52 11 3 Description of console PROGRAM VACC function 53 11 4 Description of the throttle regulation 55 11 5 Description of the battery charge detection setting 56 12 ACE0 COMBI AC0 ALARMS LIST 58 12 1 Faults diagnostic system 58 12 2 Alarms overview 59 12 3 Analysis and troub...

Страница 5: ...functions Controller for Ac 700W to 2 5 Kw AC motors Pump controller for series wounded DC motors up to 5 KW only for Combi AC0 Drivers for ON OFF electrovalves and for two proportional valves electro distributor Can bus interface Interface for canbus tiller Zapi patented sensorless and sense coil control 128 Kbytes Flash memory embedded Software downloadable via Serial link or JTAG internal conne...

Страница 6: ...ximum heatsink temperature start of the thermal cutback 85 C 4 Note 1 The DC chopper specifications are related to Combi AC0 2 2 Technical specifications Combi AC0 Power ACE0 Power Inverter for traction AC asynchronous 3 phase motors plus chopper for DC series pump motors Regenerative braking functions Digital control based upon microcontroller Voltage 24 36 48V Inverter maximum current 24V 36V 32...

Страница 7: ...AF6ZP0AL COMBIAC0 ACE0 User Manual Page 7 79 2 3 Block diagrams 2 3 1 Traction control 2 3 2 Pump control ...

Страница 8: ...itches It is suggested that microswitches have a contact resistance lower than 0 1Ohm and a leakage current lower than 100µA When full load connected the voltage between the key switch contacts must be lower than 0 1V If the microswitch to be used has different characteristic it is suggested to discuss them and their application with Zapi technicians 3 2 Analogue unit The analog input can be conne...

Страница 9: ...logue input the PEDAL WIRE KO warning is lost whose typical application is a proportional command to enable a lifting lowering function It is 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 10Kohm range Generally the load should be in the 1 5mA to 30 mA range The CPOTL CNA 30 signal r...

Страница 10: ...0 ACE0 could also be used without encoder 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 handle is specified in the home page display of the handset showing following headline CA0Z2A ZP1 00 That means CA0Z COMBIAC0 Zapi controller 2 motor s poles pair number A 32 pulses rev encoder The encoder r...

Страница 11: ...les 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 run side by side and be as short as possible 4 1 2 Contactors IT IS STRONGLY RECCOMENDED TO USE A MAIN CONTACTOR to connect and cut off the battery to the controller Depending on the setting of a param...

Страница 12: ...suggested characteristics are planarity 0 05 mm and rugosity 1 6 µm 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 dissipated For this to 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 requir...

Страница 13: ...etwork It is a communication protocol for real time control 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 electronic modules of a vehicle connected as illustrated in this image The best cable for can connections is the twisted pair if it is necessary to incre...

Страница 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 the controller that works with the highest current and the others are connected in a decreasing order of power Otherwise if two controllers are similar in power for example a traction and a pump mot...

Страница 15: ...AN 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 fewer connections analysis of problems improved easy connection with a pc to read the data flowing through the cable 4 2 4 Wirings I O connections After crimping the cable verify that all strands are...

Страница 16: ...der power supply A5 GND negative of encoder power supply A14 A phase A of encoder A13 B phase B of encoder 2 Connection of encoder with open collector output 5V power supply Connection of encoder with open collector output 12V power supply U VERY IMPORTANT It is necessary to specify in the order the type of encoder used in terms of power supply electronic output and n of pulses for revolution beca...

Страница 17: ...ower 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 battery power connection overtakes 40 more than the battery nominal voltage or if the key is switched off before the battery power line is disconnected 4 2 7 Insulation of truck frame U As stated by ...

Страница 18: ...protection 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 Protection against uncontrolled movements The main contactor will not close if The Power unit is not functioning The Logic or CANBUS interface is not functioning perfectly The Can Tiller is not operatin...

Страница 19: ...ng 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 or received by an electrical device So the analysis works in two directions 1 The study of the emission problems the disturbances generated by the device and the possible countermeasure to prevent t...

Страница 20: ...onic devices There are different solutions 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 the emissions A SOURCE OF EMISSIONS finding the main source of disturb and work on it B SHIELDING enclosing contactor and controller in a shielded box using s...

Страница 21: ... low frequency choppers with COMBI AC0 ACE0 modules The filter capacitors contained in the COMBI AC0 ACE0 module would change the SCR chopper operation and subject to excessive workload If it is necessary to use two or more control units like the chopper should be of the Zapimos family During battery recharge the COMBI AC0 ACE0 must be completely disconnected from the battery Beside changing the c...

Страница 22: ...on of parameters through the programming console Internal hour meter with values that can be displayed on the console Memory of the last five alarms with relative hour meter and temperature displayed on the console Test function within console for checking main parameters Direct communication between traction AC inverter and pump DC chopper Backing forward and reverse options are available with th...

Страница 23: ...l switch is opened The default function is the controller CUTBACK input opening the switch truck speed is reduced A7 DI6 Input of the switch DI6 The input is activated when it is connected to Batt The default function is the controller BELLY input closing the switch quick inversion function is activated A8 EV5 Output of the ON OFF electrovalve EV5 1 5 A maximum continuous current driving to Batt A...

Страница 24: ...ed horn electrovalve driver driving to Batt A27 CANL Low level CAN BUS voltage I O A28 CANH High level CAN BUS voltage I O A29 DI9 Input of the switch DI9 The input is activated when the external switch is opened The default function is the controller CUTBACK2 input opening the switch truck speed is reduced If H S FUNCTION option is PRESENT input is activate when it is connected to Batt and functi...

Страница 25: ...Zapi Flasher or for the communication with Zapi Handset or with lap top for controller setting an diagnosis 6 1 3 CNE internal connector The connector used is a 16 Vie STRIP E1 TMS JTAG interface test mode selection microcontroller input E2 5 5V JTAG interface supply E3 TD0 JTAG data output microcontroller output E4 GND JTAG interface negative reference E5 CPUCLOCK CPU clock signal for JTAG interf...

Страница 26: ...nual 7 DESCRIPTION OF POWER CONNECTIONS View of the power bars B Negative of the battery B Positive of the battery P Output of the Pump Motor U V W Connection bars of the three motor phases follow this sequence and the indication on the motor ...

Страница 27: ...AF6ZP0AL COMBIAC0 ACE0 User Manual Page 27 79 8 DRAWINGS 8 1 Mechanical drawing ...

Страница 28: ...Page 28 79 AF6ZP0AL COMBIAC0 ACE0 User Manual 8 2 Connection drawing ACE0 ...

Страница 29: ...AF6ZP0AL COMBIAC0 ACE0 User Manual Page 29 79 8 3 Connection drawing CombiAC0 ...

Страница 30: ...ey switch at the KEY input CNA 10 This is the input for the controller supply Step6 Connect the Main Contactor Coil to CNA 10 and CNA 12 The contactor must connect the battery positive to the BATT power terminal of the ACE0 COMBI AC0 Step7 Connect the motors and the minus battery to the corresponding power terminals of the ACE0 COMBI AC0 Step8 Connect the Electromechanical Brake coil between CNA 2...

Страница 31: ...in both directions Step7 Set the FREQUENCY CREEP level starting 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 Step...

Страница 32: ... has 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 Otherwise it is possible to connect a pc to the Canbus line and use the PC CAN Console software This tool is more powerful than the standard serial console The following paragraphs describe the controller configuration in the case the operat...

Страница 33: ...AF6ZP0AL COMBIAC0 ACE0 User Manual Page 33 79 10 3Description of the console menu 10 3 1 ACE0 COMBIAC0 Menu ...

Страница 34: ...Display 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 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 ...

Страница 35: ...ed but is ignored it means no action is taken when the battery is discharged Level 1 BATTERY LOW alarm is raised when the battery level is calculated being less than or equal to 10 of the full charge The BATTERY LOW alarm inhibits the Lifting function Level 2 BATTERY LOW alarm is raised when the battery level is calculated being less than or equal to 10 of the full charge The BATTERY LOW alarm red...

Страница 36: ...e load connected to CNA 9 or CNA 8 is activated When set ABSENT the diagnosis is not implemented 11 EV2 PRESENT ABSENT If set PRESENT the diagnosis EV2 DRIVER SHORTED relative to the load connected to CNA 11 is activated When set ABSENT the diagnosis is not implemented 12 EV3 PRESENT ABSENT If set PRESENT the diagnosis EV3 DRIVER SHORTED relative to the load connected to CNA 33 is activated When s...

Страница 37: ...r activated 17 M C FUNCTION PRESENT ABSENT When is set PRESENT the Main Contactor is closed after the controller key on if the initial diagnosis pass If is set ABSENT the diagnosis are masked and M C is not closed after controller Key on 18 AUX OUT FUNCTION PRESENT ABSENT When is set PRESENT the Electro mechanic Brake is driven after a traction request if all the related diagnosis pass If is set A...

Страница 38: ... MENU appears 5 ADJUSTMENTS appears on the display CONFIG MENU ADJUSTMENTS 6 Press ENTER to go into the ADJUSTMENTS MENU 7 The display will show SET BATTERY TYPE BATTERY TYPE 24V 8 Press ROLL UP or ROLL DOWN button until the desired parameter is reached 9 The desired parameter appears TROTTLE 0 ZONE 3 10 Press SET UP or SET DOWN button to modify the adjustment TROTTLE 0 ZONE 7 11 Press OUT 12 Pres...

Страница 39: ...he upper level of the battery charge table Level 0 to 9 8 LOAD HM FROM MDI When set On the HourMeter of the Controller is transferred and recorded on the HourMeter of the MDI CAN connected to CAN BUS network 9 CHECK UP DONE It can be ON OFF If it is ON it is possible to reset the last maintenance hour counter and the CHECK UP NEEDED warning 10 CHECK UP TYPE It specifies the handling of the CHECK U...

Страница 40: ...is parameter stores the PWM value applied to MC coil and AUX COIL after the first second of the output activation It is expressed in percentage of battery voltage 17 PWM ON MAIN CONT OFF the inverter applies the battery voltage to the loads on the main contactor coil connected to CNA 12 ON the PWM reduces the voltage on the main contactor coil down to the value programmed with PWM CHOP START and P...

Страница 41: ...y 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 LEVEL 2 10 When you are satisfied with the result of the changes you have made press OUT 11 The Display asks ARE YOU SURE ARE YOU SURE YES ENTER NO OUT 12 Press ENTER to accept the changes or press OUT t...

Страница 42: ...een activated The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz 8 MAX SPEED FWD Percentage It determines the maximum speed in forward direction 9 MAX SPEED BWD Percentage It determines the maximum speed in backward direction 10 HYD SPEED FINE Percentage Fine adjustment of the pump motor steering function speed 11 HYDRO COMPENSATION Percentage Adjustment of the c...

Страница 43: ... to 9 Set the maximum current for the pump motor 24 PUMP ACCELERATION DELAY In seconds Set the acceleration ramp for the pump motor 25 PUMP DECELERATION DELAY In seconds Set the deceleration ramp for the pump motor 26 SPEED LIMIT Percentage It limits the maximum speed of the lifting function Percentage of the maximum voltage applied to the pump motor 27 CREEP SPEED Percentage It sets the minimum s...

Страница 44: ...EVP2 is programmed like a On Off valve this parameter determines the fixed voltage applied on the electrovalve coil 33 EVP OPEN DELAY In seconds It defines the opening ramp of the EVP1 electrovalve when related output is set as Analog refer to Set Option menu 34 EVP CLOSE DELAY In seconds It defines the closing ramp of the EVP1 electrovalve when related output is set as Analog refer to Set Option ...

Страница 45: ...om 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 sec resolution of 0 1 HYDRO TIME Sec From 0 to 10 sec resolution of 0 1 PUMP IMAX From 50 to 100 of IMAX resolution of 5 PUMP ACC DELAY Sec From 0 to 10 sec resolution of 0 1 PUMP DEC DELAY Sec From 0 to 10 sec resolution of 0 1 SPEED LIMI...

Страница 46: ...ATURE 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 Sensing Amplifier of pump motor 6 SET CURRENT PUMP Factory adjusted This is the pump motor maximum current 7 HIGH ADDRESS To be used to have access to special memory address NOTE only Zapi technicia...

Страница 47: ...ge really supplied to the motor expressed in per cent of the actual 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 5 FREQUENCY Hz value This is the frequency of the sine wav...

Страница 48: ...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 the Tiller input is not active 17 DI1 DESCENT SWITCH ON OFF This is the level of the digital input CNA 20 for the Lowering request ON VB When it is closed to a battery key voltage the Lowering request is Active OFF GND When it is not ...

Страница 49: ...ING request is not active 24 DI8 BACKING FOR ON OFF This is the level of the digital input CNA 17 for the inching forward request ON VB When it is closed to a battery key voltage the forward inching demand is active OFF GND When it is not connected to a battery key voltage or it is connected to GND the forward inching demand is not active 25 DI9 H S SWITCH H S FUNCTION option PRESENT ON OFF This i...

Страница 50: ...WITCH ON OFF This is the level of the digital input CNA 21 ON VB When it is closed to a battery key voltage the digital input 12 is active OFF GND When it is not closed to a battery key voltage or it is connected to GND the digital input 12 is not active 30 SET POINT EVP This parameter shows the setpoint of EVP valve 31 SET POINT EVP2 Show the percentage of voltage applied to EVP2 valve 32 OUTPUT ...

Страница 51: ... the Digital Console Opening Zapi Display CA0Z2A ZP1 00 24V 200A 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 feature has been used before the type of controller data stored appea...

Страница 52: ...all 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 CA0Z2A ZP1 00 24V 200A 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 RESTORE PARAM appears on the display The Display will ...

Страница 53: ...ents 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 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 sig...

Страница 54: ...er 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 direct...

Страница 55: ...rom 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 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 MAX V...

Страница 56: ...oltage 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 Battery Discharged Detection occurs when the battery is not totally discharged it is necessary to reduce the Bat Min Adj setting as indicated in the figure below 48V NOMINAL BATTERY VOLTAGE 24V NOMINAL...

Страница 57: ...rter 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 i...

Страница 58: ... 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 occurred the first time How many hours are elapsed from the first occurrence to now How many times it has occurred in said period 12 1 Faults diagnostic system The fault diagnostic system of ACE0 COMBI AC0...

Страница 59: ...r 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 Driver which supplies Eb coil positive is high batt when the tiller switch is opened Valve pump traction stopped Lc opened Eb applied start up Valve or pump or traction request Logic Fail 1 MDI CAN 54 Overvolta...

Страница 60: ...ure the motor voltage are cheked this alarm occurs when voltage signals 3V or 2V at the init valve pump traction stopped Lc opened Eb applied init valve or pump or traction request Evp1 coil open MDI CAN 50 The Evp1 coil is not connected between Paux and NEVP1 output and the parameter EVP TYPE in the set option menu is set Analog or Digital valve pump traction stopped Lc opened Eb applied start up...

Страница 61: ... B The charging resistance is opened insert a power resistance across line contactor power terminals 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 2 VMN LOW Cause 1 start up test Before switching the LC on the software checks the power bridge it ...

Страница 62: ...onnections If motor phases windings cables have leakages towards truck frame If no problem are found on the motors the problem is inside the controller 4 POWER MOS SHORTED Cause Before switching the LC on the software checks the power bridge it turns on alternatingly the Low side and High side Power Mosfets and expects the phases voltage to decrease down to BATT increase up to Batt If the phases v...

Страница 63: ... discharge the capacitors bank If they don t discharge the fault condition is entered Troubleshooting It is suggested to verify the power contacts of LC to replace the LC is necessary 10 AUX DRIVER SHORTED Cause The driver 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 damage...

Страница 64: ...kely it is an undervoltage condition check battery charge condition power cable connection B If the alarm happens during release braking it is very likely it is due to overvoltage condition check line 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 faul...

Страница 65: ...nt raising this alarm condition C Also the electromagnetic noise on the sensor bearing can be a cause for the alarm In these cases try 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 Troubleshooting Check the harness related to CAN 1 and CAN 29 with a volt...

Страница 66: ...cts a mismatch between the valve set point and the diver voltage measured on the LOWER EVP1 output Troubleshooting Check if there is a short or a low impedance between the negative of the coil and BATT Otherwise the driver circuit is damaged and the controller must be replaced 25 EVP2 NOT OK Cause A The EVP2 driver is shorted B The microcontroller detects a mismatch between the valve set point and...

Страница 67: ...ET OPTION menu is set ANALOG or DIGITAL but no load is connected between the output and PAUX positive Troubleshooting A It is suggested to check the harness in order to verify if EVP1 coil is connected to the right connector pin and if it is not interrupted B If even connecting the coil to the right pin or replacing it the alarm is still present than the problem is inside the controller logic boar...

Страница 68: ... Cause The software was not correctly written into the flash memory or the flash memory is damaged Troubleshooting This type of fault is not related to external components replace the controller 34 CURRENT SENS KO Cause One of the current sensor used to measure the value of the current on the motor phases is damaged Troubleshooting This type of fault is not related to external components replace t...

Страница 69: ...rs continuous Motor temperature MDI CAN 65 Traction motor temperature sensor is opened if digital or has overtaken the threshold of 150 C if analog The maximum current is reduced to half and speed is reduced continuous Thermic sens ko MDI CAN 61 The output of the controller thermal sensor is out of range The maximum current is reduced to half and speed is reduced continuous Check up needed Mainten...

Страница 70: ...t of permitted stby range Pump motor stopped start up stby pump request Pump I 0 ever MDI CAN 52 Pump current feedback is always 0A even when pump motor is running Pump motor stopped pump function pump request lift lower 49 lift lower request Pump motor stopped continuous hydraulic request Cont Drv Ev1 MDI CAN 75 Driver of Ev1 is open not able to close Ev1 stopped during Ev1 function valve Ev1 req...

Страница 71: ...ilitate the troubleshooting A A travel demand 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 so when all of the above conditions were checked and nothing was found replace the controller 4 VACC NOT OK Cause The test is made at key on and after 20sec tha...

Страница 72: ...r If the alarm disappears the previously stored parameters will 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 Troubleshooting Check the thermal sensor inside the motor use the MOTOR TEMPERATURE reading in the TESTER menu check the sensor ohmic value and th...

Страница 73: ...ues which means the maximum current adjustment procedure has not been carried out yet Troubleshooting Ask the assistance of a Zapi technician to do the correct adjustment procedure of the current gain parameters 15 WAITING FOR NODE Cause The controller receives from the CAN the message that another controller in the net is in fault condition as a consequence the ACE0 COMBIAC0 controller itself can...

Страница 74: ... 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 EV3 in the Set Options menu is set PRESENT in this case the warning disappears setting the EV3 parameter ABSENT Otherwise the driver circuit is damaged and the controller must be replaced 22 EV4 DRIVER SHORTED Cause Electrovalve EV4 driver is shor...

Страница 75: ...r the problem could be in the current sensor or in the related circuit 28 RAM WARNING Cause Checksum of the ram failed Troubleshooting This fault is not related to external components 29 EEP WARNING Cause Eeprom checksum failed Troubleshooting Try to execute a CLEAR EEPROM operation refer to Console manual Switch the key off and on to check the result If the alarm occurs permanently it is necessar...

Страница 76: ...lace the controller 36 TH PROTECTION Cause The controller detected a high temperature and the performance of the motor is limited Troubleshooting It is suggested to check the cause of the high temperature Usually the controller is not correctly installed or the fan doesn t work 37 PUMP VACC NOT OK Cause The minimum of the lift potentiometer is not correctly set Troubleshooting It is suggested to r...

Страница 77: ...EV inputs use the readings in the Tester to facilitate the troubleshooting Check the microswitches for failures A failure in the logic is possible too So if you have verified through the tester that the BACKING FOR or and BACKING REV doesn t change when you depress release the correspondant switches replace the controller ...

Страница 78: ... 79 AF6ZP0AL COMBIAC0 ACE0 User Manual 13 RECOMMENDED SPARE PARTS Part number Description C12532 AMPSEAL CONNECTOR 35 pins Female C29508 SW 180 24V Single Pole Contactor C29522 SW 180 48V Single Pole Contactor ...

Страница 79: ...ent 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 requirements should be made after consulting a Zapi Agent The supplier is not responsible for any problem that arises from wiring methods that differ from information included in this Manual During p...

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