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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: zapi@zapispa.it – web: www.zapispa.it User Manual COMBIAC0 & ACE0...
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Under no circumstances will Zapi S.p.A. be held responsible to third parties for damage caused by the improper use of the present publication and of the device/devices described in it. Zapi spa reserves the right to make changes or improvements to its products at any time and without notice.
Contents INTRODUCTION ........................5 SPECIFICATION ........................6 Technical specifications Combi AC0 / ACE0 ..............6 Technical specifications Combi AC0 Power / ACE0 Power........6 Block diagrams ......................7 2.3.1 Traction control .....................7 2.3.2 Pump control....................7 SPECIFICATION FOR THE INPUT DEVICES FILLING UP THE INSTALLATION KIT..8 Digital inputs .......................8 3.1.1 DI0 ÷...
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10.4.2 Config menu “ADJUSTMENTS” functions list ..........38 10.4.3 Main menu “PARAMETER CHANGE” functions list........41 10.4.4 Zapi menu “SPECIAL ADJUSTMENTS” functions list........ 46 10.4.5 Main menu “TESTER” functions list ............47 11 OTHER FUNCTIONS ......................51 11.1 Description of console “SAVE” function ..............51 11.2...
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 connectors) or Canbus (external connector) ESD protection on CAN BUS inputs CANL and CANH AF6ZP0AL - COMBIAC0 &...
2 SPECIFICATION 2.1 Technical specifications Combi AC0 / ACE0 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):........220A (RMS) for 2' Inverter maximum current (36V, 48V):........
Zapi technicians. 3.2 Analogue unit The analog input can be connected to an accelerator unit if the Zapi can or serial tiller is not used. The accelerator unit can consist of a potentiometer or an Hall effect device.
3.3 Other analogue control unit If the Zapi can tiller is not used, input CNA#30 can be used as analogue 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.
( NPN ), push-pull. COMBI AC0 / ACE0 could also be used without encoder, sensorless control. This solution has to be discussed with Zapi technicians. Note (1): The encoder resolution and the motor poles pair (the controller can...
4 INSTALLATION HINTS In the description of these installation suggestions you will find some boxes of different colours, they mean: These are informations useful for anyone is working on the installation, or a deeper examination of the content These are Warning boxes, they describe: - operations that can lead to a failure of the electronic device or can be dangerous or harmful for the operator;...
4.1.3 Fuses Use a 6.3-10A Fuse for protection of the auxiliary circuits. For protection of the power unit, use a 350A fuse in the Battery Positive connection. For special applications or requirements these values can be reduced. For Safety reasons, we recommend the use of protected fuses in order to prevent the spread of fused particles should the fuse blow.
The COMBIAC0 module should only be connected to a traction battery. Do not use converters outputs or power supplies. For special applications please contact the nearest Zapi Service Centre. Do not connect the controller to a battery with a nominal voltage different than the value indicated on the controller label.
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Wrong Layout: Module Module Module The red lines are can wires. The black boxes are different modules, for example traction controller, pump controller and display connected by canbus. The black lines are the power cables. This is apparently a good layout, but can bring to errors in the can line. The best solution depends on the type of nodes (modules) connected in the network.
Correct Layout: Module Module Module ≈ 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 drops described before (higher diameter means lower impedance), so in this last example the cable between the minus of the Battery and the common ground point (pointed by the arrow in the image) must dimensioned taking into account...
1) COMBI AC0/ ACE0 card is fit for different types of encoder. To control AC motor with Zapi inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90°. The encoder power supply can be +5 or +12V. It can have different electronic output.
The connection of the battery line switches must be carried out following ZAPI instructions. If a mechanical battery line switch is installed, it is strongly recommended that the key supply to the inverter is open together with power battery line (see picture below);...
4.3 Protection and safety features 4.3.1 Protection features The COMBI AC0/ ACE0 is protected against some controller injuries and malfunctions: Battery polarity inversion It is necessary to fit a LINE CONTACTOR to protect the controller against reverse battery polarity and for safety reasons. Connection Errors All inputs are protected against connection errors.
ZAPI is always available to cooperate with the customer in order to evaluate installation and connection solutions. Furthermore, ZAPI is available to develop new SW or HW solutions to improve the safety of the machine, according to customer requirements.
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simulate external undesired disturbances and verify the electronic devices response. 3) The second type 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”;...
frame of a truck can works like a “local earth ground”, absorbing excess charge. So it is strongly suggested to connect to truck frame all the parts of the truck which can be touched by the operator, who is most of the time the source of ESD. 4.5 Various suggestions Never combine SCR low frequency choppers with COMBI AC0/ ACE0 modules.
Direct communication between traction AC inverter and pump DC chopper. Backing forward and reverse options are available, with the tune and the speed of the function programmable with Zapi handset. 5.1 Diagnosis The microcontrollers continually monitor the inverter and the chopper and carry out diagnostic procedures on the main functions.
6 DESCRIPTION OF THE CONNECTORS 6.1 Connectors of the logic 6.1.1 CNA external connector The connector used is an AMPSEAL plug 35 pins Input of the switch DI0. The input is activated when it is connected to +Batt. With the logic hardware properly configured it can be used to supply the EB and MC positive.
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DI11 Input of the switch DI11. The input is activated when the external switch is closed to -Batt. In the Sense Coil version this input is connected to the AC motor sense coil. Input of the switch DI5. The input is activated when it is connected to +Batt.
To connect this pin to GND (D8) for software download via serial communication. Serial communication negative reference. This internal connector is used for software download with Zapi Flasher or for the communication with Zapi Handset, or with lap-top, for controller setting an diagnosis.
7 DESCRIPTION OF POWER CONNECTIONS View of the power bars: Negative of the battery. Positive of the battery. Output of the Pump Motor. U; V; W Connection bars of the three motor phases; follow this sequence and the indication on the motor. Page - 26/79 AF6ZP0AL - COMBIAC0 &...
9 ONE SHOT INSTALLATION PROCEDURE This section of the manual describes the basic connection procedure. To move, the truck needs a minimum I/O outfit that it is mandatory: this minimum outfit is listed in the Steps from 1 to 8 below. Connect a potentiometer in the range 0.5 to 10Kohms, to modify the Step1 wished speed between +12 (CNA#25) and GND (CNA#5).
When the "Key Switch" is closed, if no alarms or errors are present, the Console Display will be showing the Standard Zapi Opening Display (Home Display). For the setting of your truck, use the procedure below.
Since the COMBIAC0/ACE0 has no external serial connector, the Zapi console 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.
Then roll until the SET OPTION item appears on the hand set display. Push the ENTER button. CA0Z2A ZP1.00 Opening Zapi Display 24V 200A 00000 Push ROLL UP + SET UP simultaneously to enter...
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1) TILLER SWITCH This option handles the input CNA#1. This input opens when the operator leaves the truck (tiller released). It is connected to a key voltage when the operator is present. There are two levels: - HANDLE: CNA#1 is managed as tiller input (no delay when released).
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ANALOG: An analogue sensor for the control of the motor temperature is connected to CNA#22. Typically the temperature sensor is a PTC (positive thermal coefficient resistance), providing the sensor characteristic to Zapi the correct table can be loaded in the controller software. DIGITAL: A digital (on/off) sensor for the motor temperature monitoring is connected to CNA#22 input.
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16) HYDRO FUNCTION KEY ON/RUNNING/NONE: Defines the activation of hydraulic steering fuction. KEY ON: the function is activated at key-on. RNNING: the function is activated during a traction or braking request. NONE: the function is never 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.
Then roll until the ADJUSTMENTS item appears on the hand set display. Push the ENTER button. CA0Z2A ZP1.00 1) Opening Zapi Menu 24V 200A 00000 2) Press Top Left & Right Buttons to enter...
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4) THROTTLE X POINT This parameter, together with the THROTTLE Y POINT, changes the characteristic of the accelerator input curve : when the accelerator is de- pressed to X point per cent, the corresponding truck speed is Y point per cent of the Maximum truck speed.
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position. 14) MAX LOWER %. This parameter stores the maximum voltage of lifting potentiometer output connected to CNA#30. The min value acquisition is done closing the DESCENT SW (DI1) and bringing the potentiometer in its min output position. 15) PWM CHOP. START %.
To enter the MAIN MENU’ it is just necessary to push the ENTER button from the home display in the hand set. CA0Z2A ZP1.00 1) Opening Zapi Menu 24V 200A 00000 ' % ' 2) Press ENTER to go into the General Menu...
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3) TILLER BRAKING Seconds. It controls the deceleration ramp when the tiller is in braking position (released). The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz 4) INVERS. BRAKING Seconds. It controls the deceleration ramp when the direction switch is inverted during travel.
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controller). 16) ACCELERATION SMOOTH It gives a parabolic form to the acceleration ramp. 17) INVERSION SMOOTH It gives a parabolic form to the acceleration ramp after a direction inversion. 18) STOP SMOOTH Hz. It sets the level of frequency where the smooth effect of the acceleration parabolic form ends.
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parameter is not effective if the EVP1 is programmed like a On/Off valve. 30) MAX EVP 0 to 100. This parameter determines the maximum voltage applied on the EVP1 when the position of the potentiometer is at the maximum. If the EVP1 is programmed like a On/Off valve this parameter determines the fixed voltage applied on the electrovalve coil.
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PROGRAMMED LEVEL PARAMETER UNIT ACCELERATION DELAY Sec. From 0 to 10 sec., resolution of 0.1 RELEASE BRAKING Sec. From 0 to 10 sec., resolution of 0.1 TILLER BRAKING Sec. From 0 to 10 sec., resolution of 0.1 INVERSION BRAKING Sec. From 0 to 10 sec., resolution of 0.1 DECEL.
10.4.4 Zapi menu “SPECIAL ADJUSTMENTS” functions list Note: the below set-up description is for skilled persons only: if you aren’t, please keep your hands off. To enter this Zapi hidden menu a special procedure is required. Ask for this procedure, directly to a Zapi technician.
10.4.5 Main menu “TESTER” functions list The TESTER functions are a real time feedback measurements of the state of the controller/motor/command devices. It is possible to know the state (active / off) of the digital I/Os, the voltage value of the analog inputs and the state of the main variables used in the motor and hydraulics control.
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when the motor temperature overtakes the MOTOR OVERTEMP setting. 12) PUMP CURRENT Ampere. It is the continuous current in the pump motor. 13) PUMP VMN It is the voltage applied to the pump motor. Expressed in percentage of the maximum voltage. 14) ACCELERATOR From 0.0V to 5.0V.
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ON +VB = When it is closed to a battery (key) voltage, the Backward Travel demand is Active. OFF GND = When it is not connected to a battery (key) voltage (or it is connected to GND), the Backward Travel demand is not active. 21) DI5/HORN SWITCH ON/OFF.
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inching demand is active. OFF GND = When it is not connected to a battery (key) voltage (or it is connected to GND), the reverse demand is not active. 28) DI11 SWITCH ON/OFF. This is the level of the CNA#18 digital input: ON GND = When CNA#18 is not closed to a battery (key) voltage (or connected to GND) the digital input#11 is active.
SAVE routine is happening SELECT: MOD. 01 When finished, the Console shows : FREE ' ' ' Press OUT to return to the Opening Zapi Display ' % ' AF6ZP0AL - COMBIAC0 & ACE0 - User Manual Page - 51/79...
Flow Chart showing how to use the RESTORE function of the Digital Console. CA0Z2A ZP1.00 Opening Zapi Display 24V 200A 00000 ' % ' Press ENTER to go into the General menu...
MAIN MENU When finished, the Console shows : RESTORE PARAM. ' ' ' Press OUT to return to the Opening Zapi Display ' % ' NOTE: in reality the SAVE and RESTORE function requires the Windows PC- Console. 11.3 Description of console “PROGRAM VACC” function This enables adjustment of the minimum and maximum useful signal level, in either direction.
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Press ENTER for yes, or OUT for NO ' % ' MAIN MENU When finished, the Console shows : PROGRAM VACC ' ' ' Press OUT to return to the Opening Zapi Display ' % ' Page - 54/79 AF6ZP0AL - COMBIAC0 & ACE0 - User Manual...
11.4 Description of the throttle regulation This regulation applies a not linear relationship between the position of the accelerator and the speed of the truck. The main goal is to increase the resolution for the speed modulation when the truck is slowly moving. Three adjustments are used for the throttle regulation: 1) THROTTLE 0 ZONE 2) THROTTLE X POINT...
11.5 Description of the battery charge detection setting The Battery Charge detection uses two setting that specify the Full Charge Voltage Level (100%) and the Discharge Voltage 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.
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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).
12 ACE0 / COMBI AC0 ALARMS LIST The ALARMS logbook in the MAIN MENU’ records the alarms of the controller. It has a FIFO (First Input First Output) structure that means the oldest alarm is lost when the database is full and a new alarm occurs. The logbook is composed of five locations getting possible to stack five different type of alarms with the following information: 1) The alarm code...
12.2 Alarms overview Machine status Restart Error Code Description Effect when the test is procedure done Capacitor Power capacitors voltage does not increase Valve, pump, traction start-up Valve or pump or charge - MDI stopped, Lc opened, Eb traction request CAN 60 applied Vmn low - MDI...
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Machine status Restart Error code Description Effect when the test is procedure done Smart driver Smart driver is open, not able to provide EB valve, pump, traction KO - MDI start-up Key re-cycle positive stopped, Lc opened CAN 68 Key-off valve, pump, traction Key-off signal is low at Key-on start-up...
12.3 Analysis and troubleshooting of microcontroller alarms To Enter the MAIN MENU’ push the Enter button at the Home Page of the hand set display and Roll for the ALARMS item. Here is the ALARMS list: 1) “CAPACITOR CHARGE” Follows the charging capacitor system: When the key is switched ON, the inverter tries to charge the power capacitors through a power resistance, and check if the capacitor are charged within a timeout.
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B) If the alarm occurs during motor running, check: Motor connections If motor phases windings/cables have leakages towards truck frame That the LC power contact closer properly, with a good contact If no problem are found on the motors, the problem is inside the controller.
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CNA#12 and –BATT. B) The driver circuit is damaged in the controller, which has to be replaced. C) The wires to the LC coil are interrupted or not connected, so check the coil related harness. 7) “CONTACTOR DRIVER” Cause: The LC coil driver is not able to drive the load. The device itself or its driving circuit is damaged.
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13) “LOGIC FAILURE #1” This fault is displayed when the controller detects an overvoltage or undervoltage condition. Overvoltage threshold is 35V, undervoltage threshold is 9,5V in the 24V controller. In 48V controller overvoltage threshold is 65V, undervoltage threshold is 9,5V. Troubleshooting of fault displayed at startup or in standby;...
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same value as the battery voltage measured with a voltmeter. If it is does not match, then do a “ADJUST BATTERY” function. C) Replace the battery. 18) “ANALOG INPUT” Cause: This alarm occurs when the A/D conversion of the analog inputs gives frozen value, on all of the converted signals, for more than 400msec.
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low value, the problem is inside the controller and the Smart Driver is probably damaged. 23) “KEYOFF SHORTED” Cause: This fault is displayed when the controller detects a low logic level of Key-Off signal during Start-Up diagnosis. Troubleshooting: It is very likely the fault is due to an under voltage, so it is suggested to check: A) Key input signal down-going pulses (below under voltage threshold) due to external loads, like DC/DC converters starting-up, relays or contactor...
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Motor connections If motor windings/cables have leakages towards truck frame That the LC power contact closer properly, with a good contact If no problem are found on the motors, the problem is inside the controller. 27) “PUMP VMN HIGH” Cause: This test is carried out when the pump motor is turning (pwm applied).
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32) “EMERGENCY” Cause: The voltage on A3 is different than +Vbatt. Troubleshooting: If A3 is correctly connected to +Vbatt. If the fuse on A3 is not damaged. 33) “FLASH CHECKSUM” Cause: The software was not correctly written into the flash memory or the flash memory is damaged.
Traction is stopped stand-by Traction acquisition procedure is in progress (NOTE: this request procedure has to be done only by Zapi test department) Pedal wire ko Accelerator poti negative (Npot) Traction is stopped start-up, stand-by, Traction MDI CAN 86 voltage is out of range (less than 0,3V...
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Machine status Restart Error code Description Effect when the test is procedure done Coil shor. Ev. - MDI Shortcircuit on On/off valves coil On/off valves stopped start-up, stby, valve on/off request CAN 76 during valve function EV1/5 driver shorted EV1 or EV2 on/off valve drivers On/off valves stopped start-up, stby valve on/off request - 74...
12.5 Analysis and troubleshooting of warnings 1) “SLIP PROFILE” Cause: There is an error on the choice of the parameters of the slip profile. Troubleshooting: Check in the hardware setting menu the value of those parameters. 2) “FORW+BACK” Cause: This alarm occurs when both the travel demands (Fwd and Bwd) or BACKING FOR and BACKING REV are active at the same time.
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6) “BATTERY LOW” Cause: It occurs when the battery charge is calculated being less than or equal to 10% of the full charge and the BATTERY CHECK setting is other than 0 (refer to SET OPTION menu). Troubleshooting: Get the battery charged. If it doesn’t work, measure with a voltmeter the battery voltage and compare it with the value in the BATTERY VOLTAGE parameter.
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The Maximum current gain parameters are at the default values, 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;...
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B) If the fault is present when the controller drives the outputs, the problem is located in the harness and in the coils. 19) “EV1/5 DRIVER SHORTED” Cause: Electrovalve EV1 or EV2 driver is shorted. Troubleshooting: Check if there is a short or a low impedence between the negative of one of those coils and –BATT.
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The EVP2 valve driver is not able to drive the load (cannot close). Troubleshooting: The device or its driving circuit is damaged, replace the controller. 26) “PUMP I NO ZERO” Cause: In standby condition (pump motor not driven), the feedback coming from the current sensor in the pump chopper gives a value out of a permitted range, because the pump current is not zero.
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The device or its driving circuit is damaged, replace the controller. 32) “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. 33) “CONT.
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FOR and BACKING REV inputs. Check the wiring of the BACKING FOR and BACKING REV 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.
13 RECOMMENDED SPARE PARTS Part number Description AMPSEAL CONNECTOR C12532 35 pins Female SW 180 24V C29508 Single Pole Contactor SW 180 48V C29522 Single Pole Contactor Page - 78/79 AF6ZP0AL - COMBIAC0 & ACE0 - User Manual...
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.
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