Zapi COMBIACX User Manual
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Zapi COMBIACX 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
User Manual
COMBIACX
&
ACEX

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Summary of Contents for Zapi COMBIACX

  • 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 COMBIACX & ACEX...
  • 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 INTRODUCTION ........................5 SPECIFICATION........................6 Technical specifications COMBIACX / ACEX............. 6 Technical specifications COMBIACX Power / ACEX 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 .......................
  • Page 4 14 PERIODIC MAINTENANCE TO BE REPEATED AT TIMES INDICATED......81 APPROVAL SIGNS COMPANY FUNCTION INIZIALS SIGN PROJECT MANAGER TECHNICAL ELECTRONIC MANAGER VISA SALES MANAGER VISA Publication N°: AFCZP0BC Edition: November 2011 Page - 4/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 5: Introduction

    1 INTRODUCTION The COMBIACX / ACEX inverter has been developed to perform all the electric functions that are usually presents in walkie and rider pallet trucks, stackers, low level order pickers. The controller can perform the following functions: Controller for AC 600W to 2 kW AC motors;...

  • Page 6: Specification

    External temperature working range:..........-40°C ÷ 40°C Maximum heatsink temperature (start of the thermal cutback)......85°C Note(1): The DC chopper specifications are related to COMBIACX only 2.2 Technical specifications COMBIACX Power / ACEX Power Inverter for traction AC asynchronous 3-phase motors plus chopper for DC series pump motors.

  • Page 7: Block Diagrams

    2.3 Block diagrams 2.3.1 Traction control 2.3.2 Pump control AFCZP0BC – COMBIACX & ACEX - User Manual Page - 7/81...

  • Page 8: Specification For The Input Devices Filling Up The Installation Kit

    Zapi technicians. 3.2 Analog 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.

  • Page 9: Other Analogue Control Unit

    3.3 Other analogue control unit If the Zapi can tiller is not used, input CNC#9 can be used as analogue input, 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.

  • Page 10: Speed Feedback

    The encoder can be of different types : power supply: +12V / +5V; electric output: open collector ( NPN ), push-pull. COMBIACX / ACEX can also operate without encoder, this using a sensorless control. This solution has to be discussed with Zapi technicians.

  • Page 11: Installation Hints

    AFCZP0BC – COMBIACX & ACEX - User Manual Page - 11/81...

  • Page 12: Fuses

    It is mandatory to avoid that the cooling air is recirculated inside the controller compartment. 4.2.2 Wirings: power cables The power cables length must be as short as possible to minimize power losses. Page - 12/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 13: Wirings: Can Connections And Possible Interferences

    They must be tightened on controller power posts with a Torque of 7 ± 1.4 Nm The COMBIACX 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.
  • Page 14 Otherwise, if two controllers are similar in power (for example a traction and a pump motor controller) and a third module works with less current, the best way to deal this configuration is to create a common ground point (star configuration) Page - 14/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 15: Wirings: I/O Connections

    “description of the connectors” AFCZP0BC – COMBIACX & ACEX - User Manual Page - 15/81...

  • Page 16: Connection Of The Encoder

    4.2.5 Connection of the encoder 1) COMBIACX/ ACEX card is fit for different types of encoder. To control an AC motor with the Zapi inverter, it is necessary to install an incremental encoder with 2 phases shifted of 90°. The encoder power supply can be +5V or +12V. It can have different electronic output.

  • Page 17: Main Contactor And Key Connection

    The connection of the main contactor can be carried out following the drawing in the figure. 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);...

  • Page 18: Protection And Safety Features

    4.3 Protection and safety features 4.3.1 Protection features The COMBIACX / ACEX 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.

  • Page 19: 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 20 C) GROUNDING: when a complete isolation cannot be achieved, a good grounding can divert the discharge current trough a “safe” path; the frame of a truck can works like a “local earth ground”, absorbing excess charge. So it Page - 20/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 21: Various Suggestions

    4.5 Various suggestions Never combine SCR low frequency choppers with COMBIACX / ACEX modules. The filter capacitors contained in the COMBIACX / ACEX module would change the SCR chopper operation and subject to excessive workload. If it is necessary to use two or more control units, like the chopper should be of the Zapimos family.

  • Page 22: Operational Features

    Error codes are provided in two ways. The digital console can be used, which gives a detailed information about the failure; the failure code is also sent on the Can-Bus. Page - 22/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 23: Description Of The Connectors

    6 DESCRIPTION OF THE CONNECTORS 6.1 Connectors of the logic The COMBIACX / ACEX inverter use four Molex Minifit connectors 6.1.1 CNA external connector Output of the protected ON/OFF electrovalve driver; 1,5 A maximum continuous current (driving to –Batt). Built-in freewheeling diode to B2.

  • Page 24: Cnb External Connector

    Input of the switch DI1. 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. NPOT Potentiometers negative reference (GND). Page - 24/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 25: Cnd External Connector

    Serial communication negative reference. This connector cannot be reached without removing the cover. It is used by Zapi for software download with Zapi Flasher, for communicating with a Zapi Handset or a lap-top, for controller setup and for diagnosis.

  • Page 26: Description Of Power Connections

    View of the power bars: Negative of the battery. Positive of the battery. Output of the Pump Motor (COMBIACX only). U; V; W Connection bars of the three motor phases; follow this sequence and the indication on the motor. Page - 26/81...

  • Page 27: Drawings

    8 DRAWINGS 8.1 Mechanical drawing COMBIACX AFCZP0BC – COMBIACX & ACEX - User Manual Page - 27/81...

  • Page 28: Mechanical Drawing Acex

    8.2 Mechanical drawing ACEX Page - 28/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 29: Connection Drawing Combiacx

    8.3 Connection drawing COMBIACX AFCZP0BC – COMBIACX & ACEX - User Manual Page - 29/81...

  • Page 30: Connection Drawing Acex

    8.4 Connection drawing ACEX Page - 30/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 31: One Shot Installation Procedure

    The Steps from 1 to 8 describe the installation operations that is mandatory to do in order your truck moves. Obviously the ACEX / COMBIACX may execute a wider set of optional services as: 1) to handle some speed reductions requests.

  • Page 32: Sequence For Ac Inverter Traction Setting

    COMBIACX/ACEX 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.
  • Page 33 Test the truck on the maximum ramp specification at full load. Step13 Make the choice for the truck behaviour on a slope. If the "Stop on Step14 ramp" option is ON, set the desired value of "auxiliary time" parameter. AFCZP0BC – COMBIACX & ACEX - User Manual Page - 33/81...

  • Page 34: Programming & Adjustments Using Digital Console

    DIGITAL CONSOLE 10.1 Adjustments via console To access and adjust all parameters it is necessary to use the Zapi console. Since the COMBIACX/ACEX 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.

  • Page 35: Description Of The Console Menu

    10.3 Description of the console menu 10.3.1 COMBIACX / ACEX Menu AFCZP0BC – COMBIACX & ACEX - User Manual Page - 35/81...

  • Page 36: Function Configuration

    ' % ' CONFIG MENU The Display will show : SET OPTIONS SET OPTIONS Press OUT again. Display now will show the ' ' ' opening Zapi menu. ' % ' Page - 36/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 37 Only when the encoder is present, it is possible to electrically hold the truck on a slope when the accelerator is released but the tiller is not released. ON: The stop on ramp feature (truck electrically hold on a ramp) is managed AFCZP0BC – COMBIACX & ACEX - User Manual Page - 37/81...
  • Page 38 9) EPS It can be set: NONE: NO EPS is present on the truck, CombiACX does not wait for CAN messages by the EPS and it does not apply EPS and braking steer cutback. OPTION#1: EPS is present and it is an EPS-AC0, ENCODER + TOGGLE SWITCHES type.

  • Page 39: Config Menu "Adjustments" Functions List

    ' ' ' MENU appears CONFIG MENU 5) ADJUSTMENTS appears on the display ADJUSTMENTS 6) Press ENTER to go into the ADJUSTMENTS ' % ' ' ' ' MENU AFCZP0BC – COMBIACX & ACEX - User Manual Page - 39/81...
  • Page 40 Adjust the lower level of the battery charge table (Level 0 to 9). 7) BAT. MAX ADJ. Adjust the upper level of the battery charge table (Level 0 to 9). Page - 40/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 41 18) EB VOLTAGE %. This parameter stores the PWM value applied to EB coil during the first second of the output activation. It is expressed in percentage of battery voltage. AFCZP0BC – COMBIACX & ACEX - User Manual Page - 41/81...
  • Page 42 %. This parameter stores the PWM value applied to the EV2 coil. It is expressed in percentage of battery voltage. 21) PWM EV3 %. This parameter stores the PWM value applied to the EV3 coil. It is expressed in percentage of battery voltage. Page - 42/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 43: Main Menu "Parameter Change" Functions List

    2) RELEASE BRAKING Seconds. It controls the deceleration ramp when the travel request is released. The parameter sets the time needed to decelerate the traction motor from 100Hz to 0Hz. AFCZP0BC – COMBIACX & ACEX - User Manual Page - 43/81...
  • Page 44 100% the speed reduction is ineffective. 14) H&S CUTBACK Typically from 10% to 100%. If H&S SWITCH option is PRESENT and POSITIVE EB option is not LEVEL 1, it determines the percentage of the max Page - 44/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 45 25) PUMP IMAX Level 0 to 9. Set the maximum current for the pump motor. 26) PUMP ACCELERATION DELAY In seconds. Set the acceleration ramp for the pump motor. AFCZP0BC – COMBIACX & ACEX - User Manual Page - 45/81...
  • Page 46 0 to 100. This parameter determines the minimum current applied on the EVP when the position of the potentiometer is at the minimum. This parameter is not effective if the EVP is programmed like a On/Off valve. Page - 46/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 47 40) EVP CLOSE DELAY Seconds. It determines the deceleration ramp on EVP. The parameter sets the time needed to decrease the current from the maximum possible value to zero. AFCZP0BC – COMBIACX & ACEX - User Manual Page - 47/81...
  • Page 48 From 0% to 100%, resolution of 0.1% EVP OPEN DELAY Sec. From 0 to 25.5 sec., resolution of 0.1 EVP CLOSE DELAY Sec. From 0 to 25.5 sec., resolution of 0.1 Page - 48/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 49: Zapi Menu "Special Adjustments" Functions List

    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.

  • Page 50: Main Menu "Tester" Functions List

    Percentage value. It supplies the residual charge of the battery as a percentage of the full charge level. 9) TEMPERATURE °C value. This is the temperature of the inverter base plate. This temperature is used for the HIGH TEMPERATURE alarm detection. Page - 50/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 51 Active. OFF GND = When it is not connected to a battery (key) voltage (or it is connected to GND), the Forward Travel demand is not active. AFCZP0BC – COMBIACX & ACEX - User Manual Page - 51/81...
  • Page 52 GND) the 2ND request is not active. 26) DI11/CUTBACK1 ON/OFF. This is the level of the CNA#7 digital input: ON GND = When CNA#7 is not closed to GND the CUTBACK1 request not is active. Page - 52/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 53 ON/OFF. This is the HORN output command. 36) MAIN CONT. VOLT. %. This is the main contactor output command (voltage %). 37) ELEC. BRAKE VOLT. %. This is the electrobrake output command (voltage %). AFCZP0BC – COMBIACX & ACEX - User Manual Page - 53/81...

  • Page 54: Other Functions

    SAVE routine is happening SELECT: MOD. 01 When finished, the Console shows : FREE ' ' ' Press OUT to return to the Opening Zapi Display ' % ' Page - 54/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 55: Description Of Console "Restore" Function

    SELECT : MOD. 00 ACEX ZAPI V1 ' % ' Press ENTER to commence the Restore operation ' ' ' ARE YOU SURE? The Display will ask “ARE YOU SURE”. YES=ENTER NO=OUT AFCZP0BC – COMBIACX & ACEX - User Manual Page - 55/81...

  • Page 56: Description Of Console "Program Vacc" Function

    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.
  • Page 57 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 ' % ' AFCZP0BC – COMBIACX & ACEX - User Manual Page - 57/81...

  • Page 58: Description Of The Throttle Regulation

    From the X point up to the MAX VACC point, the slope of the relationship between the truck speed and the accelerator position is different (see figure below) to match the full speed in the truck with the MAX VACC voltage in the accelerator position. Page - 58/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 59: Description Of The Battery Charge Detection Setting

    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 BATTERY VOLTAGE AFCZP0BC – COMBIACX & ACEX - User Manual Page - 59/81...
  • Page 60 5) After key on battery charge can be only increased if the battery charge computed after key on is greater than the last value stored in Eeprom the battery charge value is updated otherwise the Battery charge is not updated. Page - 60/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 61: Combiacx /Acex Alarms List

    - How many times it has occurred in said period. 12.1 Faults diagnostic system The fault diagnostic system of COMBIACX / ACEX controller is divided into 2 main groups of faults: ALARMS: these are the faults which open the power section, which means the power bridge is opened and, when possible, the LC is opened and EB is applied.

  • Page 62: Alarms Overview

    One of two (or both) Watchdog circuit outputs Valve, pump, traction start-up, stby, Key re-cycle MDI CAN 08 becomes high due to an HW or SW problem stopped, Lc opened, Eb traction applied Page - 62/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 63 Pump vmn not ok - Pump motor output voltage is Lc opened, Eb applied MDI CAN 32 different than expected AFCZP0BC – COMBIACX & ACEX - User Manual Page - 63/81...
  • Page 64 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 Page - 64/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 65 This alarm occurs when there is a short circuit of one of the coils connected to outputs of the COMBIACX / ACEX (LC coil or EB coil). After the overload condition has been removed, the alarm exits automatically by releasing and then enabling a travel demand.
  • Page 66 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 36/48V controller overvoltage threshold is 65V, Page - 66/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 67 If it is does not match, then do a “ADJUST BATTERY” function. C) Replace the battery. 18) “ANALOG INPUT” AFCZP0BC – COMBIACX & ACEX - User Manual Page - 67/81...
  • Page 68 B) If, even disconnecting the wire from the connector pin, the output stays at low value, the problem is inside the controller and the Smart Driver is probably damaged. 23) “KEYOFF SHORTED” Cause: Page - 68/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 69 It is suggested to check: A) Motor connections B) If motor windings/cables have leakages towards truck frame C) If no problem are found on the motors, the problem is inside the controller AFCZP0BC – COMBIACX & ACEX - User Manual Page - 69/81...
  • Page 70 If it is too low, this alarm occours. Troubleshooting: Please check Motor internal connections (ohmic continuity) Motor power cables connections Motor leakage to truck frame If the motor connections are OK, the problem is inside the controller Page - 70/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 71 “WAIT MOTOR STILL” warning (see in the warnings chapter) Motor internal connections Motor power cables connections Motor leakage to truck frame If the motor connections are ok, the problem is inside the controller AFCZP0BC – COMBIACX & ACEX - User Manual Page - 71/81...

  • Page 72: Warnings Overview

    Waiting for A Canbus network node is in alarm continuous node - MDI condition. uC is waiting for it to CAN 68 resolve its error condition. Page - 72/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 73 EVP request Wait mot. P. still - The software waits for the motor Valve, pump, traction start-up None MDI CAN 63 pump to stop stopped, LC opened, Eb applied AFCZP0BC – COMBIACX & ACEX - User Manual Page - 73/81...

  • Page 74: Analysis And Troubleshooting Of Warnings

    Improve the air cooling of the controller. If the alarm is signalled when the controller is cold, the possible reasons are a thermal sensor failure or a failure in the logic card. In this case, it is necessary to replace the controller. Page - 74/81 AFCZP0BC- COMBIACX & ACEX - User Manual...
  • Page 75 The alarm ends when the acquisition is done. 12) “TILLER OPEN” Cause: Warning: when the tiller is released, after a fixed period of time of standby (30 seconds) the main contactor open. Troubleshooting: AFCZP0BC – COMBIACX & ACEX - User Manual Page - 75/81...
  • Page 76 The controller receives from the CAN the message that another controller in the net is in fault condition; as a consequence the ACEX / COMBIACX controller itself cannot enter an operative status, but has to WAIT for the other controller coming out from the fault status.
  • Page 77 26) “VACC OUT RANGE” Cause: The voltage on CNC#4 is outside of the parameters’ range. Troubleshooting: Please re-acquire the VACC parameters with a PROGRAM VACC procedure. 27) “STALL ROTOR” AFCZP0BC – COMBIACX & ACEX - User Manual Page - 77/81...
  • Page 78 If the EVP TYPE parameter is set to ANALOG, please acquire again the values of MIN LOWER and MAX LOWER. If the controller is in Combiacx configuration and the PROPORTION. LIFT parameter is set to ON, please acquire again also the values of MIN LIFT and MAX LIFT.
  • Page 79 If the motor connected to –P is still moving, just wait for it to be still. If not, in 30 seconds the alarm “PUMP VMN NOT OK” will appear. Please see the alarms chapter. AFCZP0BC – COMBIACX & ACEX - User Manual Page - 79/81...

  • Page 80: Recommended Spare Parts

    Protected 300A strip fuse COMBIACX 24/36/48V C16587 Protected 300A strip UL fuse C16505 Protected 355A strip fuse COMBIACX PW 24/36/48V C16588 Protected 350A strip UL fuse C16520 10A 20mm control circuit fuse Page - 80/81 AFCZP0BC- COMBIACX & ACEX - User Manual...

  • Page 81: Periodic Maintenance To Be Repeated At Times Indicated

    During periodic checks, if a technician finds any situation that could cause damage or compromise safety, the matter should be bought to the attention of a Zapi Agent immediately. The Agent will then take the decision regarding operational safety of the machine.

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