Zapi ACE0 2mC User Manual
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Zapi ACE0 2mC User Manual

Zapi ACE0 2mC User Manual

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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
EN
COMBIAC0 2µC
Publication: AF6ZP0CA
Edition: March 1, 2018
User Manual
ACE0 2µC

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Summary of Contents for Zapi ACE0 2mC

  • Page 1 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 ACE0 2µC COMBIAC0 2µC Publication: AF6ZP0CA...
  • Page 2 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.

  • Page 3: Table Of Contents

    Contents 1  INTRODUCTION ........................6  1.1  About this document ....................6  1.1.1  Scope of this manual ..................6  1.1.2  Manual revision ..................... 6  1.1.3  Warnings and notes ..................6  1.2  About the controller ..................... 7  1.2.1  Safety ......................7  1.2.2  OEM’s Responsibility ..................
  • Page 4 5.2  Installation of the hardware ..................35  5.2.1  Positioning and cooling of the controller ............. 35  5.2.2  Wirings: CAN bus connections and possible interferences ......36  5.2.3  Wirings: I/O connections ................38  5.2.4  Connection of an encoder ................39  5.2.5  Connection of a sin/cos sensor ..............
  • Page 5 13.1.6  Steer acquiring ..................144  13.1.7  Tester Functionality ................... 144  13.1.8  Alarm Logbook ..................145  13.2  Appendix B: Zapi Smart Console user guide ............146  13.2.1  Operational Modes ..................146  13.2.2  The keyboard .................... 146  13.2.3  Home Screen .................... 147 ...

  • Page 6: Introduction

    1.1.2 Manual revision This revision replaces all previous revisions of this document. Zapi has put much effort to ensure that this document is complete and accurate at the time of printing. In accordance with Zapi policy of continuous product improvement, all data in this document are subject to change or correction without prior notice.

  • Page 7: About The Controller

    1.2 About the controller 1.2.1 Safety Zapi provides this and other manuals to assist manufacturers in using the motor controller in a proper, efficient and safe manner. Manufacturers must ensure that all people responsible for the design and use of equipment employing the motor controller have the proper professional skills and equipment knowledge.

  • Page 8: Specifications

     Software downloadable via serial link (internal connector) or CAN bus (external connector).  Diagnostic provided via CAN bus using Zapi PC CAN Console.  Rugged sealed housing and connectors meet IP65 environmental sealing standards for use in harsh environments.

  • Page 9: Current Ratings

    2.3 Current ratings Maximum Continuous Nominal DC DC maximum Model 2-min rated rated current voltage current [A] current [Arms] [Arms] ACE0 36/48V COMBIAC0 36/48V 36/48V ACE0 PW 36/48V 36/48V COMBIAC0 PW 36/48V Combinations of DC choppers and 3-phase inverters different from those reported in the previous table are also available.

  • Page 10: Voltage Ratings

    2.4 Voltage ratings Nominal DC voltage 36/48V Conventional working voltage range 19.2 V ÷ 28.8 V 28.8 V ÷ 57.6 V 57.8 V ÷ 96 V Non-operational overvoltage limits 115V Non-operational undervoltage limits Conventionally, the controller can be set to operate without alarm in the range from 80% to 120% of the nominal battery voltage.

  • Page 11: Drawings

    3 DRAWINGS 3.1 Mechanical drawings 3.1.1 Base plate version AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 11/155...

  • Page 12: Longitudinal Heat Sink Version

    3.1.2 Longitudinal heat sink version Page – 12/155 AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual...

  • Page 13: Connection Drawings

    3.2 Connection drawings 3.2.1 AC Traction configuration AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 13/155...

  • Page 14: Ac Pump Configuration

    3.2.2 AC Pump configuration Page – 14/155 AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual...

  • Page 15: Ac Can Open Configuration

    3.2.3 AC CAN Open configuration AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 15/155...

  • Page 16: Pmsm Traction Configuration

    3.2.4 PMSM Traction configuration Page – 16/155 AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual...

  • Page 17: Pmsm Pump Configuration

    3.2.5 PMSM Pump configuration AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 17/155...

  • Page 18: O Interface Description

    The following table lists the functional associations for the pins of the 35-poles Ampseal connector. For each I/O pin, the default Zapi function is indicated. The function of each pin can be changed in customized software. Some I/O pins can have special functionalities depending on the controller configuration.
  • Page 19 Type Name Description Digital input DI0. The input is activated when it is connected to +B. With the logic Input hardware properly configured it can be used to supply the positive terminals of EB and MC. The default function is as TILLER input. Positive supply of the electromechanical brake.
  • Page 20 Type Name Description Analog input 1. Input CPOT1 The default function is as accelerator reference (wiper contact of the accelerator potentiometer). Digital input DI10. The input is activated when it is connected to +B. Input DI10 The default function is as 2ND input, closing the switch valve EV2 is activated.

  • Page 21: Internal Connector

    Type Name Description Output CANL Low-level CAN bus line. Output CANH High-level CAN bus line. Digital input DI9. Input The input is activated when the external switch is opened. The default function is as LIFT DC CUTBACK input. Analog input for the lift/lower potentiometer. If PEDAL BRK ANALOG = ON this input is used as analog brake Input CPOT2...

  • Page 22: External Devices

    (like CUTBACK) must be normally closed, so that each associated function becomes active when the microswitch opens. Nominal voltage figures for digital inputs in standard Zapi configuration are listed in the following table. Custom hardware may feature different voltage values.
  • Page 23 Protection Each digital input has a 22 nF capacitor to -B for ESD protection. Circuit Input impedance of digital inputs in standard Zapi configurations are listed below. Custom hardware may feature different impedance values. Inverter voltage 24 V...

  • Page 24: Analog Inputs

    10-bits analog-to-digital converter (resolution is given by the voltage excursion over 1024 levels). Circuit Input impedance and maximum frequency for analog inputs in standard Zapi configurations are listed below. Custom hardware may feature different values. Inverter voltage...

  • Page 25: Special Inputs

    If an analog input is used as a speed feedback, a system safety strategy must be defined. The application software takes care of analog input errors such as VACC OUT OF RANGE or VACC NOT OK. See paragraph 10.3. 4.4.4 Special inputs Special inputs normally configured as digital inputs active to -B are available on pins and A21.

  • Page 26: Mc Output

    Connector position A13, A14. It is important to verify the wiring and to ensure that encoder signals are not disturbed by the motor currents or by the electric motor brake. For more details about encoder installation see also paragraph 5.2.4. Note: encoder resolution and motor pole pairs are specified in the Console home page, which shows a headline like the following: A0MT2B...
  • Page 27 PWM frequency can be changed by software. However, if a different PWM frequency has to be used it is suggested to discuss it with Zapi technicians. Protection Protected against inductive discharge with internal freewheeling diode to the...

  • Page 28: Eb Output

    Please ensure that inductive loads are connected so that the paths through the freewheeling diodes are always present; otherwise use external freewheeling diodes. Use of brushless fan or other loads with built-in capacitors may lead to high inrush currents at turn-on, which may eventually bring to open-drain overcurrent trips.

  • Page 29: Auxiliary Outputs

    EB output can be only a PWM voltage-controlled output. It cannot be used as current-controlled output. For version different from 24V, it is suggested to discuss with Zapi technicians about the supply of pin A2. Driving an inductive load on a PWM open-drain output, make sure to have always a path for the current through the freewheeling diode.
  • Page 30  Up to 1 Arms continuous (hold current) and max 2 A peak (pull current) for a maximum duration of 200 ms.  Individual hardware for EV1 for driver shorted and driver open detection. HORN output has not feedback hardware circuit. Any fault diagnosis is not available but an self-protected driver is used PWM Voltage controlled Outputs features ...

  • Page 31: High-Side Driver

    The shunt resistor for overcurrent protection is shared among EV1, EV2, EV3, EV4 and EV5 output. The overcurrent threshold is fixed by hardware to 9 A. The maximum total continuous current when outputs EV1, EV2, EV3, EV4, and EV5 are active at the same time is 3 A. The maximum total peak current is 9 A.

  • Page 32: Motor Temperature Measurement Input

    Connector position 4.4.10 Motor temperature measurement input Input for motor-temperature sensor, for measuring the temperature of motor windings, is available on pin PTH A22. Compatible temperature sensors are like: - KTY84 with 1000Ω @ 100°C. - KTY83 with 1670Ω @ 100°C. - PT1000 with 1385Ω...

  • Page 33: Can Bus

    potentiometers is available on pin in substitution of EV5 output. Output voltage is configurable via hardware by internal jumper to +12V or +5V; maximum output current is 100 mA. Actual values for “+12V” and “+5V” are respectively 13.1 V ± 0.5 V and 5 V ±...

  • Page 34: Installation Hints

    5 INSTALLATION HINTS This section presents a general procedure for startup and verification of ACE0/COMBIAC0 controller after installation on a vehicle. The motor controller is a software configurable device. In a CAN supervisor system, some or all aspects of setup and operations may be managed by a vehicle master controller communicating over the CAN bus.

  • Page 35: Installation Of The Hardware

    Selection of appropriate fuse ratings is a system design issue and falls under the OEMs responsibility. The fuse is not intended to protect the motor controller or motor against overloads. 5.2 Installation of the hardware Before doing any operation, ensure that the battery is disconnected. For traction applications, raise up or otherwise disable driving wheels to prevent the possibility of unexpected vehicle motion or motion in the wrong direction during initial commissioning.

  • Page 36: Wirings: Can Bus Connections And Possible Interferences

    5.2.2 Wirings: CAN bus connections and possible interferences CAN stands for Controller Area Network. CAN bus is a communication protocol for real time control applications. CAN bus operates at data rate of up to 1 Mbit/s. It was invented by the German company Bosch to be used in the automotive industry to permit communication among the various electronic modules of vehicle, connected as illustrated in the following image.
  • Page 37 Wrong Layout: Can bus Power cables Module Module Module Red lines are CAN bus wires. Black boxes are different modules, for example a traction controller, a pump controller and a display connected via CAN bus. Black lines are the power cables. This is apparently a good layout, but actually it can bring to errors onto the CAN line.

  • Page 38: Wirings: I/O Connections

    Correct Layout: Can bus Power cables Module Module Centre of the Ground connection Module Note: Module 1 power ≈ Module 2 power > Module 3 power In this case, the power cables of the two similar controllers must be as short as possible.

  • Page 39: Connection Of An Encoder

    The number of pulses/rev can be properly set using the dedicated parameters (see paragraph 8.2.5). The maximum speed detectable by standard hardware configuration can be limited depending on number of pulse/rev. Contact Zapi technician for checking this aspect. VERY IMPORTANT...

  • Page 40: Connection Of A Sin/Cos Sensor

    (trapezoidal waves). A PMSM is a BLDC when, by turning its shaft lightened, the electromotive force between two motor terminals is of trapezoidal shape. To control BLDC motor with Zapi inverter, it is necessary to three Hall sensors. Hall sensors power supply can be +5 or +12 V. +5V/+12V Positive power supply.

  • Page 41: Connection Of Main Contactor And Key Switch

    VERY IMPORTANT Since the logic unit and the software must be set in the correct way by Zapi lines, it is absolutely mandatory to specify in the commercial order the type of Hall sensors used (in terms of supply voltage, output voltage and number of pulses per revolution), their configuration in the d-axis rotor orientation and their sequence around one turn.

  • Page 42: Emc

    Special attention must be given to lengths, paths and shielding of the electric connections. These aspects are beyond of Zapi control. Zapi can offer assistance and suggestions on EMC related problems, basing on its long experience. However, ZAPI declines any responsibility for non-compliance, malfunctions and failures, if correct testing is not made.

  • Page 43: Various Suggestions

    IMPORTANT NOTE: it is always much easier and cheaper to avoid ESD from being generated, rather than increasing the level of immunity of the electronic devices. There are different solutions for EMC issues, depending on the required level of emissions/ immunity, the type of controller, materials and position of the wires and electronic components.

  • Page 44: Features

    High efficiency of motor and battery due to high-frequency commutations. Double microcontroller for safety functions. Self-diagnosis with faults that can be displayed through the console (Smart console, PC CAN Console) or Zapi MDI/Display. Modification of parameters through the programming console (Smart console, PC CAN Console).

  • Page 45: Dual Traction Motor

    6.2 Dual traction motor In the case of dual traction motors, there is additional processing of the associated steering signal (from a potentiometer or switches) in order to generate separate torque demands for the left and right motors of the vehicle. This allows the two motors to be operated at different speeds, which greatly assists in turning the vehicle and prevents wheel scrub.

  • Page 46: Safety Features

    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.

  • Page 47: Start-Up Hints

    7 START-UP HINTS 7.1 Check prior to initial power up For traction applications, raise up or otherwise disable drive wheels to prevent the possibility of unexpected vehicle motion or motion in the wrong direction during initial commissioning. For hydraulic applications, open the valve to prevent the possibility of excessive pressure to build-up (in the event of a malfunction of the pressure-relief valve).

  • Page 48: Set-Up Procedure For Ac Traction Inverter

    Zapi Console. When the key switch is closed, if no alarms or errors are present, the Console display shows the standard Zapi opening line. For the setting of your truck, use the procedure below. If you need to reply the same settings on different controllers, use the SAVE and RESTORE sequence.

  • Page 49: Set-Up Procedure For Ac Pump Inverter

    Use the TESTER function to monitor the motor speed for the next steps. Activate the TILLER and FW (or BW) microswitches. Motor starts running in open-loop mode. Because of the open-loop mode, it is normal if the reported speed is not perfectly stable, but value on display must be, in any case, quite fixed.
  • Page 50 Set the maximum current for lift and lowering in MAX. CURRENT TRA and MAX. CURRENT BRK (see paragraph 8.2.1). Set the motor-related parameters. It is suggested to discuss them with Zapi technicians. Set parameter SET MOT.TEMPERAT according to the type of motor thermal sensor adopted.

  • Page 51: Programming & Adjustements

    Zapi PC CAN Console. To connect the Zapi Smart Console (or old hand console) through a remote module, like a Zapi tiller card of a Zapi display. This module is to be connected to the same CAN bus line of the inverter.

  • Page 52: Settings Overview

    8.1 Settings overview Inverter settings are defined by a wide set of parameters, organized as follows. SPECIAL PARAMETER CHANGE SET OPTIONS ADJUSTMENT HARDWARE SETTING ADJUSTMENT ACC. TORQUE DEL. HM DISPLAY OPT. SET BATTERY ADJUSTMENT #01 TOP MAX SPEED DEC. TORQUE DEL. HM CUSTOM 1 OPT.

  • Page 53: Settings Description

    CO = CANopen controller N = None The parameters and the functionalities described in the following paragraphs are referred to ZAPI Standard software. They could be different in any other customized software releases depending on customer requests. 8.2.1 PARAMETER CHANGE...
  • Page 54 PARAMETER CHANGE Parameter Allowable range Description 0.1 s ÷ 25.5 s This parameter defines the deceleration ramp performed TILLER BRAKING after the tiller/seat switch is released, i.e. the time needed (T, TM) (steps of 0.1 s) to decelerate the motor from 100 Hz down to 0 Hz. A special software feature manages the deceleration ramp depending on the starting speed (see paragraph 9.5).
  • Page 55 PARAMETER CHANGE Parameter Allowable range Description 0% ÷ 100% This parameter defines the speed of the pump motor when 3RD PUMP SPEED speed is requested. It represents a percentage of the (steps of 1%) maximum pump speed. 0% ÷ 100% This parameter defines the speed of the pump motor when 4TH PUMP SPEED speed is requested.
  • Page 56 PARAMETER CHANGE Parameter Allowable range Description 1 ÷ 5 This parameter defines the acceleration profile: 1 results in ACC SMOOTH a linear ramp, higher values result in smoother parabolic (T, TM, P, CO) (steps of 0.1) profiles. 1 ÷ 5 This parameter defines the acceleration profile performed INV SMOOTH when the truck changes direction: 1 results in a linear...
  • Page 57 PARAMETER CHANGE Parameter Allowable range Description 0 s ÷ 12.75 s It determines the current decrease rate on EVP. The EVP CLOSE DELAY parameter sets the time needed to decrease the current (steps of 0.05 s) from the maximum possible value to zero. 0% ÷...
  • Page 58 HYDRO SETTINGS Parameter Allowable range Description 0.1 s ÷ 25.5 s It defines the deceleration ramp for the pump motor. PU. DECELER. DEL (steps of 0.1 s) 0% ÷ 100% It limits the maximum speed of the lifting function. In MAX SPEED LIFTDC particular, it defines the voltage applied to the pump motor (steps of 1%)

  • Page 59: Set Options

    8.2.2 SET OPTIONS SET OPTIONS Parameter Allowable range Description 0 ÷ 6 This parameter defines the configuration for the hour meter HM DISPLAY OPT. shown on a display (i.e. MDI). The possible settings are the (T, TM, P, CO) same described for parameter HM CUSTOM 1 OPT.. 0 ÷...
  • Page 60 SET OPTIONS Parameter Allowable range Description 0 ÷ 3 This option specifies the management of the low battery BATTERY CHECK charge situation. There are four levels of intervention: (T, TM, P, CO) 0 = The battery charge level is evaluated but ignored, meaning that no action is taken when the battery runs out.
  • Page 61 SET OPTIONS Parameter Allowable range Description OFF ÷ ON This parameter enables or disables the control of the SOFT LANDING deceleration rate of the truck when the accelerator is released. ON = When the accelerator is released, the inverter controls the deceleration rate of the truck through the application of a linearly decreasing torque curve.
  • Page 62 SET OPTIONS Parameter Allowable range Description 0 ÷ 11 This parameter decides the feature of the main MAIN POT. TYPE potentiometer, connected to pin A15. (T, TM) Pot. Low to High / Direction Enable En. dead type High to Low switches switch band...
  • Page 63 SET OPTIONS Parameter Allowable range Description NONE ÷ ANALOG It allows to select which type of steering unit is connected to STEERING TYPE the controller. (T, TM) NONE = NO steering module is present on the truck, ACE0/COMBIAC0 does not wait for CAN message by the EPS and it does not apply EPS and braking steer cutback.
  • Page 64 SET OPTIONS Parameter Allowable range Description NONE, BRAKE This parameter enables or disables the NEB output (A4), AUX OUT FUNCTION dedicated to the electromechanical brake. NONE = Diagnoses are masked and E.B. is not driven upon a traction request. BRAKE = E.B. is driven upon a traction request if all the related diagnoses pass.
  • Page 65 SET OPTIONS Parameter Allowable range Description NONE ÷ DIGITAL This parameter defines the behavior of output EVP2 (A23). EVP2 TYPE NONE = Output is not enabled. ANALOG = Output manages a PWM current- controlled proportional valve. DIGITAL = Output manages an on/off valve. ABSENT ÷...
  • Page 66 If the steering performance of the truck do not match your requirements even if you have defined the right truck geometry, contact a Zapi technician in order to establish if a custom steering table has to be created. 0 ÷ 32000...

  • Page 67: Adjustments

    (Only for BLE0 with Motor). sin/cos or PWM sens) Contact Zapi technicians for a detailed description of the acquisition procedure. IMPORTANT NOTE: output EV5 may be not available depending on hardware configuration even if the parameter EV5 is set as PRESENT.
  • Page 68 ADJUSTMENTS Parameter Allowable range Description 0 V ÷ 25.5 V It records the minimum value of lifting potentiometer when MIN LIFT DC the lift switch is closed. (steps of 0.1V) (Read Only) See paragraph 9.2. (T, TM, TS, P) 0 V ÷ 25.5 V It records the maximum value of lifting potentiometer when MAX LIFT DC the lift switch is closed.
  • Page 69 ADJUSTMENTS Parameter Allowable range Description -12.8% ÷ 12.7% Adjusts the level of the battery charge table at start-up, in BDI ADJ STARTUP order to calculate the battery charge at key-on. (T, TM, P, CO) (steps of 0.1%) See paragraph 9.10. 0% ÷...
  • Page 70 ADJUSTMENTS Parameter Allowable range Description 0 ÷ 255 This parameter defines the coefficient used for evaluating SPEED FACTOR the truck speed (in km/h) from the motor frequency (in Hz), (T, TM, CO) (steps of 1) according to the following formula: ⁄...
  • Page 71 ADJUSTMENTS Parameter Allowable range Description 0% ÷ 100% This parameter defines the duty-cycle of the PWM applied PWM EV2 to EV2 output (A11). (255 steps) 0% ÷ 100% This parameter defines the duty-cycle of the PWM applied PWM EV3 to EV3 output (A33). (255 steps) 60°C ÷...

  • Page 72: Special Adjust

    Note: SPECIAL ADJUST. must only be accessed by skilled people. To change settings in this group of settings, a special procedure is needed. Ask for this procedure directly to a Zapi technician. In SPECIAL ADJUST. there are factory-adjusted parameters that should be changed by expert technicians only.
  • Page 73 Allowable range Description 0% ÷ 255% Gain of the pump-motor current-sensing amplifier. ADJUSTMENT #03 NOTE: only Zapi technicians can change this value through (Read Only) a special procedure. See table on the right This is the pump motor maximum current.
  • Page 74 OFF ÷ ON This parameter enables or disables the console to change RS232 CONSOLLE settings. NOTE: only Zapi technicians can change this value. 0 ÷ 56 This parameter defines the offset of the CANopen frame ID CANOPEN OFST IDs.

  • Page 75: Hardware Setting

    Note: only Zapi technicians can change this value. 8.2.5 HARDWARE SETTING The HARDWARE SETTINGS parameters group includes the motor-control- related parameters. Only those parameters the user can modify are here described. For descriptions and teaching about missing parameters contact a Zapi technician. HARDWARE SETTING Parameter Allowable range Description 0 Hz ÷...
  • Page 76 32, 48, 64, 80, 64, 128, 256, 512, 1024 NOTE: with standard HW, the capability to use encoders with high number of pulses could be limited depending on the speed. Ask to Zapi technician before to operate on this parameter Page – 76/155...

  • Page 77: Tester Function

    32, 48, 64, 80, 64, 128, 256, 512, 1024 NOTE: with standard HW, the capability to use encoders with high number of pulses could be limited depending on the speed. Ask to Zapi technician before to operate on this parameter 1 ÷ 30 This parameter defines the number of pole pairs of the MOTOR P.
  • Page 78 TESTER (Master µC) Unit of measure Parameter Description (resolution) Ampere (1 A) Estimation of the DC current the inverter is drawing from DC BUS CURRENT the battery. Percentage (1%) Estimation of the battery charge based on the battery BATTERY CHARGE voltage.
  • Page 79 TESTER (Master µC) Unit of measure Parameter Description (resolution) Ampere (1 A) Maximum value of the q-axis current component, IQIMAX LIM. BRK according to braking-related settings, expressed in root-mean-square Ampere. ON, OFF Flag for any current limitation being active, for example FLAGS LIMITATION thermal current cutback, maximum current reached, etc.
  • Page 80 TESTER (Master µC) Unit of measure Parameter Description (resolution) OFF/ON Status of the backward input (pin A31). DI4-A31 BW SW (T, TM) OFF/ON Status of the backward input (pin A31), when the inching DI4-A31 BW-INCH function is enabled. (TS) OFF/ON Status of the digital input 5 (pin A19), dedicated to the horn DI5-A19 HORN (not for BLE0).
  • Page 81 TESTER (Master µC) Unit of measure Parameter Description (resolution) OFF/ON Status of the digital input 2 (pin A6), dedicated to the DI2-A6 HYDRO SW hydraulic request (for ACE0/COMBIAC0 configured as pump controller). OFF/ON Status of the digital input 3 (pin A32), dedicated to the lift DI3-A32 LFT/E SW function (for ACE0/COMBIAC0 configured as pump controller).
  • Page 82 TESTER (Master µC) Unit of measure Parameter Description (resolution) 0 ÷ 65535 Status word travelling over CAN bus. STATUS WORD (CO) 0 ÷ 65535 Warning code (in case of warning). WARNING SYSTEM (CO) % (1%) Setpoint of the proportional electrovalve EVP1 transmitted TARGET EVP1 over CAN bus.
  • Page 83 TESTER (Master µC) Unit of measure Parameter Description (resolution) OFF/ON Status of the EV1 output (pin A9). A9 OUTPUT EV1 OFF/ON Status of the EV2 output (pin A11). A11 OUTPUT EV2 OFF/ON Status of the EV3 output (pin A33). A33 OUTPUT EV3 OFF/ON Status of the EV4 output A34.
  • Page 84 (T, TM, CO) km (1 km) Odometer: overall distance traveled by the truck. ODOMETER KM (T, TM, CO) Reserved for Zapi technicians use. CPU TIME F US Reserved for Zapi technicians use. CPU TIME M US Page – 84/155 AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual...

  • Page 85: Tester - Supervisor Microcontroller

    8.3.2 TESTER – Supervisor microcontroller The following table lists the supervisor microcontroller data that can be monitored through the TESTER function. TESTER (Supervisor µC) Unit of measure Parameter Description (resolution) Hertz (0.1 Hz) Motor speed measured through the encoder and MEASURED SPEED expressed in the same unit of FREQUENCY (Hz).
  • Page 86 TESTER (Supervisor µC) Unit of measure Parameter Description (resolution) Volt (0.01 V) Status of the analog input 1 (pin A15). A15 POT#1 Volt (0.01 V) Status of the analog input 2 (pin A30). A30 POT#2 Volt (0.01 V) Status of the analog input 3 (pin A18), when the D11-A18 POT#3 associated hardware is configured as analog input.

  • Page 87: Other Functions

    Before ‘PROGRAM VACC’ After ‘PROGRAM VACC’ PROGRAM VACC can be carried out through Zapi PC CAN Console or through Zapi Smart Console. For the step-by-step procedures of the two cases, refer to paragraphs 13.1.4 or 13.2.6. 9.2 PROGRAM LIFT / LOWER function This function allows to adjust the minimum and maximum useful signal levels of lift and lowering request.

  • Page 88: Program Steer Function

    MAX LOWER See paragraphs 13.1.5 or 13.2.7 for the acquiring procedure. 9.3 PROGRAM STEER function This enables the adjustment of the minimum and maximum useful signal levels of the steering control. This function is useful when it is necessary to compensate for asymmetry with the mechanical elements associated with the steering.

  • Page 89: Braking Time

    Acceleration time. 9.5 Braking time The DECEL. BRAKING parameter allows to define the deceleration rate depending on the final-speed setpoint. Deceleration time is evaluated differently by software for speed steps greater or smaller than 100 Hz. Case 1 (black trace in the graph): ...
  • Page 90 Braking delay. Note: This example is valid for all the braking-related parameters: DECEL. BRAKING, INVER. BRAKING, RELEASE BRAKING, TILLER BRAKING, PEDAL BRAKING, SPEED LIMIT BRK, STEER BRAKING. Page – 90/155 AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual...

  • Page 91: Acceleration Smoothness

    9.6 Acceleration smoothness Smoothing-related parameters define a parabolic profile for the acceleration or deceleration ramps close to 0 rpm. Values have not a phisycal meaning: 1 means linear ramp, higher values (up to 5) result in smoother accelerations. Acceleration smoothness. Note: This example is valid for ACC SMOOTH, BRK SMOOTH, INV SMOOTH.

  • Page 92: Description Of The Throttle Regulation

     CURVE SPEED 1 = 50%  CURVE CUTBACK = 30%  STEER DEAD ANGLE = 40°  STEER ANGLE 1 = 50°  STEER ANGLE 2 = 80° This set of parameters define the speed profile depicted in the graph below. Steering curve.

  • Page 93: Nmc & Neb Output

    Throttle signal Speed setpoint [% of MAX VACC] [% of MAX VACC] FREQUENCY CREEP THROTTLE 0 ZONE FREQUENCY CREEP THROTTLE X1 POINT THROTTLE Y1 POINT THROTTLE X2 POINT THROTTLE Y2 POINT THROTTLE X3 POINT THROTTLE Y3 POINT MAX VACC MAX SPEED The following graph better displays the throttle –...

  • Page 94: Battery-Charge Detection

    NMC & NEB output management. Example 1: MC VOLTAGE = 100% MC VOLTAGE RED = 70% Contactor is closed by applying 100% of duty-cycle to the coil and then then it is reduced to 70%. Example 2: MC VOLTAGE = 70% MC VOLTAGE RED.

  • Page 95: Evp Setup

    parameter. The battery-charge detection works as the following procedure. Start-up 1) The battery voltage is read from key input when the battery current is zero, which is when the output power stage is not driven. It is evaluated as the average value over a window of time, hereafter addressed as Vbatt.
  • Page 96 EVP management If the valve is set as ON-OFF the MIN EVP parameter is disabled and the current set point applied to the valve is only dependent by MAX EVP. The dynamic delay seen during the modification of the current set point, in both cases, ANALOG Valve and ON/OFF Valve, is dependent by the OPEN DELAY and CLOSE DELAY parameters (see paragraph 8.2.1).

  • Page 97: Torque Profile

    The current is immediately set to the MIN EVP and then it is increased up to MAX EVP in the time set by the OPEN DELAY parameter. In the same way, if the actual set point applied is the maximum and the lowering request is removed all at once, the current is reduced to minimum with a time delay equal to CLOSE DELAY and then is set to zero.
  • Page 98 Torque curves. Page – 98/155 AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual...

  • Page 99: Steering Table

    9.13 Steering Table Steering table allows to automatically calibrate the rotation applied to the steering wheels so to obtain the desired steering angle of the truck. The STEER TABLE parameter defines whether to adopt a custom or predefined steering table: ...

  • Page 100: Motor Thermal Protection

    9.14 Motor thermal protection The controller performs a thermal protection of the driven motor by monitoring its temperature and applying a linear cutback to the maximum current when it becomes excessive. Thermal protection can be tuned setting parameters MAX. MOTOR TEMP., STOP MOTOR TEMP.

  • Page 101: Diagnostic System

    10 DIAGNOSTIC SYSTEM The diagnostic system of ACE0/CombiAC0 provides the operator with information about a wide set of faults or problem that the controller can encounter.  Faults which cause the power section to stop, meaning the power bridge opens and, when possible, the main contactor opens and the electromechanical brake is applied.
  • Page 102 The microcontroller constantly monitors the inverter and carries out a diagnostic procedure on the main functions. For simple visual diagnosis of system faults and to monitor system status, a red LED is provided on the body of the controller. Alarm LED At start-up it is turned ON for 2 seconds and then it stays continuously OFF when there is no fault.

  • Page 103: Alarms From Master Μc

    Diagnosis is provided in two ways: the console can be used, which gives detailed information about the failure, but the failure code is also sent on the CAN bus. 10.3 Alarms from master µC MDI / Restart ZAPI Error code Effect Condition OPEN...
  • Page 104 MDI / Restart ZAPI Error code Effect Condition OPEN procedure CODE CODE CODE ENCODER D.ERR XX Traction is stopped running Key re-cycle FFA9 MC is opened , EB is applied, HOME SENS.ERR XX Running Key re-cycle FFB0 EVP stopped EB is applied, Traction/Pump, Perform ABS OFFSET SPD.SENS.
  • Page 105 MDI / Restart ZAPI Error code Effect Condition OPEN procedure CODE CODE CODE Start-up, stand-by, COIL SHOR. EVAUX Valves stopped Valves request FFF1 running Valves or MC is not closed, EB is applied, Start-up, stand-by, LC COIL OPEN Traction/Pump FFE6...
  • Page 106 MDI / Restart ZAPI Error code Effect Condition OPEN procedure CODE CODE CODE Valve, pump, traction stopped, Start-up FFBA WAIT MOT.P STILL LC opened, EB applied Start-up, stand-by, Traction/Pump HANDBRAKE FFDD Traction/Pump motor is stopped running request MC is not closed, EB is applied, Traction/Pump MOT.PHASE SH.

  • Page 107: Troubleshooting Of Alarms From Master Μc

    MDI / Restart ZAPI Error code Effect Condition OPEN procedure CODE CODE CODE MC is opened (the command is Valves or Start-up, stand-by, CONTACTOR DRIVER released), EB is applied, Traction/Pump 3221 running Traction/Pump, valves stopped request Start-up Valves or MC is opened, EB is applied, (immediately after MC-EF COIL SHOR.
  • Page 108 ACQUIRING A.S. (MDI/LED code = 2) Cause: Controller is acquiring data from the absolute feedback sensor. Troubleshooting: The alarm ends when the acquisition is done. ACQUIRE END (MDI/LED code = 2) Cause: Absolute feedback sensor acquired. ANALOG INPUT (MDI/LED code = 96) Cause This alarm occurs when the A/D conversion of the analog inputs returns frozen values, on all the converted signals, for more than 400 ms.
  • Page 109 If the battery is actually charged, measure the battery voltage through a voltmeter and compare it with the BATTERY VOLTAGE reading in the TESTER function. If they are different, adjust the ADJUST BATTERY parameter (ADJUSTMENTS list, paragraph 8.2.3) with the value measured through the voltmeter.
  • Page 110 Check the connections between the controller outputs and the loads. Collect information about characteristics of the coil connected 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.
  • Page 111 According with this “sign”, only the customized firmware can be uploaded. Troubleshooting Upload the correct firmware. Ask for assistance to a Zapi technician in order to verify that the firmware is correct. AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual...
  • Page 112 Troubleshooting: Ask for assistance to a Zapi technician in order to do the adjustment procedure of the current gain parameters. DATA ACQUISITION (MDI/LED code = 0) Cause: Controller in calibration state.
  • Page 113 If the motor direction is correct, swap A and B signals. If the motor direction is not correct, swap two of the motor cables. If the problem is not solved, contact a Zapi technician. ENCODER ERROR (MDI/LED code = 82)
  • Page 114 Ask for 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.
  • Page 115 Ask for 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.
  • Page 116 (ABI encoder). It is caused by a wrong acquisition of the angle offset between the orientation of the rotor and the index signal. The hexadecimal value “XX” facilitates Zapi technicians debugging the problem.
  • Page 117 The error between the Iq (q-axis current) setpoint and the estimated Iq is out of range. Troubleshooting Ask for assistance to a Zapi technician in order to do the correct adjustment of the motor parameters. LC COIL OPEN (MDI/LED code = 22)
  • Page 118 Troubleshooting Check the wiring, in order to verify if LC coil is connected to the right connector pin and if it is not interrupted. If the alarm is still present, than the problem is inside the logic board; replace it. LIFT+LOWER (MDI/LED code = 49) Cause: Both the pump requests (LIFT and LOWER) are active at the same time.
  • Page 119 M/S PAR CHK MISM (MDI/LED code = 97) Cause: At start-up there is a mismatch in the parameter checksum between the master and the supervisor microcontrollers. Troubleshooting: Restore and save again the parameters list. MOT.PHASE SH. XX (MDI/LED code = 47) Cause Short circuit between two motor phases.
  • Page 120 Cause The motor current has overcome the limit fixed by hardware. Troubleshooting If the alarm condition occurs again, ask for assistance to a Zapi technician. The fault condition could be affected by wrong adjustments of motor parameters. PARAM RESTORE (MDI/LED code = 14) Cause: The controller has restored the default settings.
  • Page 121 Cause The error between the power setpoint and the estimated power is out of range. Troubleshooting Ask for assistance to a Zapi technician about the correct adjustment of the motor parameters. POWERMOS SHORTED (MDI/LED code = 89) Cause The DC-link voltage drops to zero when a high-side or low-side MOSFET is turned on.
  • Page 122 In case the problem is not solved, replace the controller. PUMP VACC NOT OK (MDI/LED code = 50) Cause: The minimum voltage of the lift potentiometer is not correctly set. Troubleshooting: It is suggested to repeat the acquiring procedure of MIN LIFT and MAX LIFT (see paragraph 9.2).
  • Page 123 The motor connected to -P must be completely still before this alarm occurs. The software waits 30 seconds before showing this alarm. During this time it shows the WAIT MOTOR STILL warning. Motor internal connections Motor power cables connections Motor leakage to truck frame If the motor connections are ok, the problem is inside the controller it is necessary to replace the logic board.
  • Page 124 Cause: This alarm occurs only when the controller is configured as PMSM and the feedback sensor selected is sin/cos. The signal coming from sin/cos sensor has a wrong direction. The hexadecimal value “XX” facilitates Zapi technicians debugging the problem. Troubleshooting: Check the wirings.
  • Page 125 If no problem is found on the motor or on the speed sensor, the problem is inside the controller, it is necessary to replace the logic board. SMARTDRIVER KO (MDI/LED code = 69) Cause: There is a hardware problem in the smart driver circuit (high-side driver on pin A2).
  • Page 126 Troubleshooting: It is necessary to improve the controller cooling. To realize an adequate cooling in case of finned heat sink important factors are the air flux and the cooling-air temperature. If the thermal dissipation is realized by applying the controller base plate onto the truck frame, the important factors are the thickness of the frame and the planarity and roughness of its surface.
  • Page 127 Troubleshooting: Check in the HARDWARE SETTINGS list the value of those parameters. VACC NOT OK (MDI/LED code = 78) Cause: At key-on and immediately after that, the travel demands have been turned off. This alarm occurs if the ACCELERATOR reading (in TESTER function) is above the minimum value acquired during the PROGRAM VACC procedure.
  • Page 128 Troubleshooting Check that the battery has the same nominal voltage of the inverter. Check the battery voltage, if it is out of range replace the battery. If the battery voltage is ok, replace the logic board. VKEY OFF SHORTED (MDI/LED code = 20) Cause At key-on, the logic board measures a voltage value of the KEY input that is constantly out of range, below the minimum allowed value.
  • Page 129 if the motor connections are OK, the problem is inside the controller; replace it. If the alarm occurs while the motor is running, check: motor connections; that the LC power contact closes properly, with a good contact; if no problem is found, the problem is inside the controller. Replace it. WAIT MOTOR STILL (MDI/LED code = 45) Cause: The controller is waiting for the motor to stop rotating.
  • Page 130 ADJUSTMENTS list, record the value stored as HARDWARE BATTERY RANGE parameter in the SPECIAL ADJUST. list and contact a Zapi technician. Through the TESTER function, check that the KEY VOLTAGE reading shows the same value as the key voltage measured with a voltmeter on pin A10.

  • Page 131: Alarms From Supervisor Μc

    10.4 Alarms from supervisor µC MDI / Error Restart ZAPI Effect Condition OPEN procedure CODE Code CODE CODE Start-up, stand-by, BUMPER STOP FFC7 Traction sopped running MC is opened, EB is applied, WATCHDOG Stand-by, running Key re-cycle 6010 traction/pump stopped...
  • Page 132 According with this “sign”, only the customized firmware can be uploaded. Troubleshooting Upload the correct firmware. Ask for assistance to a Zapi technician 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.
  • Page 133 Cause: This is a safety related test. Supervisor μC has detected that master μC is driving the traction motor in a wrong way (not corresponding to the operator request). The hexadecimal value “XX” facilitates Zapi technicians debugging the problem. Troubleshooting: Checks the matching of the parameters between Master and Supervisor.
  • Page 134 (not corresponding to the operator request). Troubleshooting: Checks the matching of the parameters between Master and Supervisor. Ask for assistance to a Zapi technician. If the problem is not solved, replace the logic board. PARAM RESTORE (MDI/LED code = 14) Cause: The controller has restored the default settings.
  • Page 135 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 the logic board. WATCHDOG (MDI/LED code = 8) Cause: This is a safety related test.

  • Page 136: Info Code For Electrovalves

    WRONG SLAVE VER. (MDI/LED code = 91) Cause: Wrong software version on supervisor uC. Troubleshooting: Upload the correct software version or ask for assistance to a Zapi technician. 10.5 Info code for electrovalves Errors related to HW circuits driving electrovalves (CONT DRV. EV, DRV. SHOR.

  • Page 137: Spare Parts

    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 Contactor AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 137/155...

  • Page 138: Periodic Maintenance

    The installation of this electronic controller should be made according to the diagrams included in this Manual. Any variations or special modifications should be evaluated with a Zapi Agent. The supplier is not responsible for any problem that arises from connections that differ from information included in this Manual.

  • Page 139: Appendices

    The description contained in the next paragraph focuses on the basic information about the connection and change of parameters. For additional functionalities available for both tools it is suggested to contact Zapi technicians in order to receive more detailed information or dedicated documentation. 13.1 Appendix A: PC CAN Console user guide Windows Pc CAN Console uses standard Zapi communication protocol to display inverter’s information.
  • Page 140 From this form you can define the CAN-device used (IXXAT or IFAK or Peak) and the CAN communication speed then press the OK 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”...

  • Page 141: Parameter Download

    Write the Password -> “ZAPI” 13.1.2 Parameter download Once 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 downloaded automatically.

  • Page 142: How To Modify The Parameters

    13.1.3 How to modify the parameters Before doing any change, save the old parameters set by clicking over “File” > “Save” and give to the file an understandable name. The complete list of parameters will be saved as a .csv file in order to be opened with Microsoft Excel®...

  • Page 143: Program Vacc

    13.1.4 Program Vacc Choose “Function” > “Program VACC” menu. When “Acquire” is pressed, the PROGRAM VACC procedure will start:  Select the Enable switch, if any;  Select the direction switch (either forward or backward);  Press the pedal up to its maximum excursion. Displayed values will vary accordingly to operator inputs.

  • Page 144: Steer Acquiring

    Select the Enable switch, if any; Select the control switch (either lift or lower); Move the control sensor (lift/lower potentiometer) to the correct position according to what you are acquiring; Press “Stop Teach” button. The procedure is the same for all the lift and lower potentiometers. 13.1.6 Steer acquiring Once you are connected you need to receive the inverter’s parameter;...

  • Page 145: Alarm Logbook

    13.1.8 Alarm Logbook This window will display the alarms stored in the controller. 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 user can clear alarm logbook on inverter EEPROM;...

  • Page 146: Appendix B: Zapi Smart Console User Guide

     Baud-rate selectable;  Zapi can provide the serial cable compatible with Molex SPOX connector used in Console Ultra. CAN bus connection The Smart Console can connect to an existing CAN line and connect with any Zapi controller inside this line.

  • Page 147: Home Screen

    Green LED can blink in certain cases which will be described better in following sections. 13.2.3 Home Screen After showing the Zapi logo, the HOME SCREEN will appear on the display: AF6ZP0CA – COMBIAC0 & ACE0 2uC – User Manual Page – 147/155...

  • Page 148: Connected

    From top:  First line tells which firmware version is running inside the console, in this case ZP 0.15;  RS232 Console: enter this menu to start a serial connection as in the Console Ultra;  CAN Console: enter this menu to establish a CAN connection; ...

  • Page 149: How To Modify A Parameter

    MAIN MENU contains the complete list of menus available in the controller. Contrary to Console Ultra there are no “hidden” menus which must be reached by pressing many buttons all at once: now all menus are visible. Use UP and DOWN keys to navigate the list: once you find the desired menu press OK to enter it.

  • Page 150: Program Vacc

    Description above is valid for every menu which contains parameters and options like SET OPTIONS, ADJUSTMENTS, HARDWARE SETTINGS, etc. . 13.2.6 Program VACC Program VACC menu has been slightly modified compared with old console. Upon entering this menu the console will show the current programmed values. When OK is pressed PROGRAM VACC procedure will start: console will invite you: ...

  • Page 151: Lift And Lower Commands Acquiring

    When ESC is pressed, console will ask if programmed values must be saved or discarded. 13.2.7 Lift and Lower commands acquiring From MAIN MENU enter the Adjustment menu. With UP and DOWN keys you can scroll the whole list: once you have highlighted a value that you want acquire press OK.

  • Page 152: Steer Command Acquiring

    13.2.8 Steer command acquiring From MAIN MENU enter the Adjustment menu. The procedure 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 keys to scroll the list as usual.

  • Page 153: Download Parameter List To Usb Stick

    Five is the maximum number of alarm codes which is stored inside the controller. Colors are used to separate recurrent alarm codes from rare events. In order of increasing frequency, alarm names can be:  White: up to 5 occurrences. ...
  • Page 154 Download procedure After entering SAVE PARAMETER TO USB the Smart Console will check the presence of the USB stick. If the stick is not connected yet, it will ask the operator to connect one. When the stick is present, the display will show the content, starting from the root directory (/) of the filesystem.
  • Page 155 go to step 3. If it is not present, a new subdirectory will be created automatically. Do not enter the subdirectory 3. Press OK to start parameter download. A progression bar shows the process. 4. When finished, press 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).

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